Footwear with plates and method of using a three-dimensional printer and a compression mold to manufacture plates for footwear products

Abstract

A method of manufacturing a component for a sole structure of an article of footwear includes providing a printer having a platform, a first head receiving a first supply, and a second head receiving a second supply. The method further includes printing a base layer on the platform, the base layer including a substrate material and defining a longitudinal axis. The method further includes continuously printing a first fiber layer on the base layer, the first fiber layer defining a first fiber orientation disposed at a first angle relative to the longitudinal axis, and continuously printing a second fiber layer on the first fiber layer, the second fiber layer defining a second fiber orientation disposed at a second angle relative to the longitudinal axis. The first angle is different from the second angle.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of and priority to U.S. Application No. 17 / 578,752, filed January 19, 2022, which is incorporated by reference herein in its entirety.

[0002] [Federally Sponsored Research and Development Reference] N / A

[0003] [Sequence table] N / A

[0004] The present disclosure relates generally to footwear having a plate, and more specifically, to footwear having a plate formed by an additive manufacturing process to have a customized reinforcement and propulsion pattern. [Background technology]

[0005] Most conventional shoes and footwear generally include an upper and a sole attached to the lower end of the upper. Conventional shoes further include an internal space, i.e., a void or cavity, formed by the inner surface of the upper and the sole, which receives the user's foot before the shoe is secured to the foot. The sole is attached to the bottom surface or boundary of the upper and is located between the upper and the ground. As a result, the sole typically provides the user with stability and cushioning while wearing the shoe. In some cases, the sole may include multiple components, such as an outsole, a midsole, and an upper. For example, the sole may include a particular foam material that provides increased stability at one or more desired locations along the sole, or a foam material that reduces stress and impact energy on the foot or leg while the user is running, walking, or engaging in another activity. The sole may also include additional components, such as a plate embedded in the sole to increase the overall stiffness of the sole and reduce energy loss during use.

[0006] The upper generally extends upward from the sole and defines an interior cavity that completely or partially encases the foot. In many cases, the upper spans the instep area and the toe area, as well as the medial and lateral sides of the foot. Many footwear items may also include a tongue that extends across the instep area to fill the gap between the medial and lateral edges of the upper. The tongue may also be located below the lacing system and between the medial and lateral sides of the upper to allow adjustment of the tightness of the shoe. The tongue may further be operable by the user to move the foot in and out of the interior space or cavity. Additionally, the lacing system may allow the user to adjust certain dimensions of the upper and / or sole, thereby allowing the upper to accommodate a wide variety of foot shapes having different sizes and shapes.

[0007] The sole may include a wide variety of materials selected based on one or more intended uses of the shoe. The sole may also include portions of different materials specialized for specific areas of the upper. For example, the front and heel portions of the sole may be more resistant or stiffer, providing more stability. Other portions of the shoe may be softer to provide flexibility, cushioning, and conformity to the user's foot. Additionally, people who suffer from flat feet or other special foot conditions often insert insoles into their shoes to provide more targeted support. Thus, because user preferences vary widely, a shoe is desired that can be customized to provide cushioning, support, and stiffness along various portions, directions, and zones of the shoe. Summary of the Invention [Problem to be solved by the invention]

[0008] However, while many currently available shoes have a variety of features related to the above characteristics, many shoes have sole structures that suffer from a lack of customization, as they include sole structures manufactured in standard sizes and shapes. Additionally, many athletic shoes, particularly running shoes, are manufactured in a manner that creates a significant amount of waste.

[0009] Thus, what is desired is an article of footwear that has features that lend themselves to customized characteristics and that are manufactured with a minimal amount of waste. These and other shortcomings of the prior art are outlined in the following disclosures: [Means for solving the problem]

[0010] Many advantages of the articles of footwear described herein will be apparent to those skilled in the art. The articles of footwear described herein can have a variety of configurations. The articles of footwear can have an upper and a sole structure coupled to the upper.

[0011] In some embodiments, a method for manufacturing a component for a sole structure of an article of footwear includes providing a printer having a platform, a first head receiving a first supply, and a second head receiving a second supply. The method further includes printing a base layer on the platform, the base layer being made of a substrate and defining a longitudinal axis. The method further includes printing a first fiber layer on the base layer in a continuous manner, the first fiber layer defining a first fiber orientation disposed at a first angle relative to the longitudinal axis, and printing a second fiber layer on the first fiber layer in a continuous manner, the second fiber layer defining a second fiber orientation disposed at a second angle relative to the longitudinal axis. The first angle is different from the second angle. The method also includes subjecting the printed model to a compression molding process. The printed model includes at least a base layer, a first fiber layer, and a second fiber layer.

[0012] In some embodiments, the first fiber layer comprises at least 60% of the substrate. In other embodiments, the second fiber layer comprises at least 50% of the fiber material. Furthermore, the first fiber layer and the second fiber layer define different layer volumes. In some embodiments, the first fiber layer comprises at least one of carbon fiber, aramid fiber, boron fiber, or glass fiber. In some embodiments, the printed model comprises at least five fiber layers. The printed model comprises an arch segment extending between the rear segment and the front segment. Further, a transparent resin is applied to the printed model in the compression mold. The printed model comprises a third fiber layer defining a third fiber orientation disposed at a third angle relative to the longitudinal axis, the third angle being equal to the first angle, and the second fiber layer being separated from the first fiber layer by the second fiber layer.

[0013] In some embodiments, a plate is provided for a sole structure of an article of footwear including an upper having an insole. The plate includes an inner surface facing an outer surface, a heel end facing a toe end, a base layer including a substrate material, and a plurality of composite layers coupled to the base layer. Each composite layer includes a first volume of substrate and a second volume of fiber material. The first volume of substrate material and the second volume of fiber material are different. Each composite layer defines a fiber orientation, and the fiber orientation differs between adjacent composite layers. The plate is printed layer by layer to define a top surface and a bottom surface, and at least a portion of the top surface is spaced apart from the insole of the upper.

[0014] In some embodiments, the composite plies are arranged in a stack between the top and bottom surfaces of the plate, the stack having quasi-isotropic properties. Each composite ply has anisotropic properties, the anisotropy differing between adjacent composite plies. The anisotropy includes at least one of bending resistance, torsional resistance, or tensile stiffness. The first volume of substrate is smaller than the second volume of fibrous material. The second volume of fibrous material includes at least one of carbon fiber, aramid fiber, boron fiber, or glass fiber.

[0015] In yet another aspect, a method of using a three dimensional printer and compression mold to manufacture a plate for an article of footwear includes providing a supply of substrate material to a first head of the printer, providing a supply of fabric material to a second head of the printer, providing a preformed model on a platform within the printer, and providing a design model to the printer. The first head and the second head are selectively activated and deactivated to print at least two composite layers on the preformed model. The at least two composite layers are separated from the preformed model and received within the compression mold.

[0016] In some embodiments, each of the at least two composite layers includes a continuous fiber strand provided by the second head. The plate includes a front segment having a first stiffness, an arch segment having a second stiffness, and a rear segment having a third stiffness. The first stiffness is greater than the second stiffness and the third stiffness is greater than the first stiffness. The first stiffness, the second stiffness, and the third stiffness are equal.

[0017] Other aspects of the articles of footwear, including features and advantages of the articles of footwear, will become apparent to one of ordinary skill in the art upon review of the figures and detailed description herein, and thus, all such aspects of the articles of footwear are intended to be included in the detailed description and this summary. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a perspective view of a bottom and medial side of an article of footwear configured as a right shoe including an upper and a sole structure according to one embodiment of the disclosure. [Diagram 2] FIG. 2 is a top view of the article of footwear of FIG. [Diagram 3] FIG. 3 is a top view of the article of footwear of FIG. 1 with the upper removed and the skeletal structure of a user's foot superimposed thereon. [Figure 4] 4 is an exploded perspective view of the article of footwear of FIG. 1 showing a plate according to an embodiment of the present disclosure. [Figure 5A] FIG. 5A is a cross-sectional view of the plate taken along line 5-5 of FIG. [Figure 5B] 5B is a cross-sectional view of the article of footwear taken along line 5-5 of FIG. [Figure 6] FIG. 6 is a graph showing the relationship between the elastic modulus and the volume fraction of the fibers. [Figure 7] FIG. 7 is a schematic diagram of a printer used for additive manufacturing of a plate according to one embodiment of the present disclosure. [Figure 8A] FIG. 8A is a flow diagram illustrating a process for printing a plate according to an embodiment of the present disclosure. [Figure 8B] FIG. 8B is a flow diagram illustrating a process for printing a plate according to an embodiment of the present disclosure. [Figure 9A] FIG. 9A is a schematic diagram of the components of a compression mold. [Figure 9B] FIG. 9B is a schematic diagram of the components of a compression mold. [Figure 10] FIG. 10 is a schematic diagram of a top view of several layers of another embodiment of a footwear product plate that has undergone an exemplary manufacturing process. [Figure 11] FIG. 11 is a schematic diagram of a top view of several layers of a production plate for footwear in another embodiment that has undergone an exemplary manufacturing process. [Figure 12] FIG. 12 is a schematic diagram of a top view of several layers of a production plate for footwear in another embodiment that has undergone an exemplary manufacturing process. [Figure 13] FIG. 13 is a schematic diagram of a top view of several layers of a production plate for footwear in another embodiment that has undergone an exemplary manufacturing process. [Figure 14] FIG. 14 is a schematic diagram of a top view of several layers of a production plate for footwear in another embodiment that has undergone an exemplary manufacturing process. [Figure 15] FIG. 15 is a schematic diagram of a top view of several layers of a production plate for footwear in another embodiment that has undergone an exemplary manufacturing process. [Figure 16]FIG. 16 is a schematic diagram of a top view of several layers of a production plate for footwear in another embodiment that has undergone an exemplary manufacturing process. [Figure 17] FIG. 17 is a schematic diagram of a top view of several layers of a production plate for footwear in another embodiment, as it undergoes an exemplary manufacturing process. [Figure 18] FIG. 18 is an exploded view of another embodiment of a sole structure incorporating yet another embodiment of a plate. [Figure 19] FIG. 19 is a schematic side view of yet another embodiment of a plate, the plate being configured as an outsole having traction elements. [Figure 20] FIG. 20 is a schematic diagram of a cross section of the traction element taken along line 20-20 of FIG. [Figure 21] FIG. 21 is a schematic diagram of the top view of the opening in the plate of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] The following description and accompanying figures disclose various embodiments or configurations of shoes and sole structures. Although the embodiments of shoes or sole structures are disclosed with reference to sports shoes, such as running shoes, tennis shoes, and basketball shoes, the concepts associated with the embodiments of shoes or sole structures can be applied to a wide range of footwear and footwear forms, such as, for example, cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and cleats, walking shoes, and track cleats. The concepts of shoes and sole structures can also be applied to non-athletic footwear, such as dress shoes, sandals, loafers, slippers, and heels. In addition to footwear, certain concepts described herein can also be applied to and incorporated into other types of clothing or other athletic equipment, including helmets, padding or protective padding, shin guards, and gloves. Furthermore, certain concepts described herein can be incorporated into cushions, backpack straps, golf clubs, or other consumer or industrial products. Thus, the concepts described herein can be utilized in a variety of products.

[0020] The term "about" as used herein refers to variations in numerical quantities that may result, for example, from typical measuring and manufacturing procedures used in footwear or other articles of manufacture that may include embodiments disclosed herein, from inadvertent errors in these procedures, from differences in manufacture, source, or purity of ingredients used to make a composition or mixture or to carry out a method. Throughout this disclosure, the terms "about" and "approximately" refer to a range of values ​​of ±5% of the numerical value that the term precedes.

[0021] The present disclosure is directed to articles of footwear and / or specific components of articles of footwear, such as uppers and / or soles or sole structures. The uppers may be comprised of knitted components, woven fabrics, and / or nonwoven fabrics. Knitted components can be produced by knitting yarns, woven fabrics can be produced by weaving yarns, and nonwoven fabrics can be produced by manufacturing integral nonwoven fabrics. Knitted fabrics include fabrics formed by warp knitting, weft knitting, flat knitting, circular knitting, and / or other suitable knitting methods. Knitted fabrics can have, for example, plain knit construction, mesh knit construction, and / or rib knit construction. Woven fabrics include fabrics formed by any of a number of weaving forms, such as, for example, but not limited to, plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weave, and / or double cloth weave. Nonwoven fabrics include fabrics made by, for example, airlaid and / or spunlaid processes. The uppers may be comprised of various materials, such as first yarn, second yarn, and / or third yarn, which may have different properties or different visual properties.

[0022] 1-3 illustrate an exemplary embodiment of footwear 100 configured as a shoe including an upper 102 and a sole structure 104. Upper 102 is attached to sole structure 104, which together define an interior cavity 106 (see FIGS. 2 and 3) into which a foot may be inserted. For reference, footwear 100 defines a forefoot region 108, a midregion 110, and a heel region 112 (see FIGS. 2 and 3). Forefoot region 108 generally corresponds to the portion of footwear 100 that encases portions of the foot including the toes, ball of the foot, and the joints connecting the metatarsals to the toes or phalanges. Midregion 110 is adjacent and contiguous to forefoot region 108 and generally corresponds to the portion of footwear 100 that encases the arch of the foot along with the arch of the foot. The heel region 112 is proximate and adjacent to the central region 110 and generally corresponds to a portion of the footwear 100 that wraps around the rear of the foot, including the heel or calcaneus, ankle, and / or Achilles tendon. A longitudinal axis V extends through the central region 110 of the footwear 100 and defines a vertical plane that is disposed between the forefoot region 108 and the heel region 112. A longitudinal axis L extends through the sole 104 of the footwear 100 and into the forefoot region 108, the central region 110, and the heel region 112. The longitudinal axis L defines a longitudinal plane that is generally perpendicular to the vertical plane of the longitudinal axis V, and the longitudinal plane L may be disposed tangentially or flush with a portion of the sole 104.

[0023] Although only one shoe 100 is depicted, i.e., a shoe worn on a user's right foot, it should be understood that the concepts disclosed herein are applicable to a pair of shoes (not shown), including a left shoe and a right shoe sized and shaped to receive a user's left and right feet, respectively. However, for ease of disclosure, a single shoe is referenced to illustrate aspects of the present disclosure, but the following disclosure with reference to footwear 100 is applicable to both the left and right shoes. However, in some embodiments, there may be differences between the left and right shoes other than the left / right configuration. Additionally, in some embodiments, the left shoe may include one or more additional components that the right shoe does not include, and vice versa.

[0024] Many conventional footwear uppers are formed from multiple components, such as textiles, polymer foams, polymer sheets, leather, and synthetic leather, which are joined by gluing or stitching at seams. In some embodiments, the upper 102 of the footwear 100 is formed from a knit construction or knitted components. In various embodiments, the knitted components can incorporate different types of yarns that can impart different properties to the upper. For example, one region of the upper 102 may be formed from a first type of yarn that imparts a first set of properties, and another region of the upper 102 may be formed from a second type of yarn that imparts a second set of properties. With this configuration, the properties of the upper 102 can be varied throughout the upper 102 by selecting specific yarns for different regions of the upper 102.

[0025] With reference to the material(s) that make up the upper 102, the particular properties that a particular type of yarn brings to the knitted component region may depend at least in part on the materials forming the various filaments and fibers of the yarn. For example, cotton may impart a soft effect, biodegradability, or natural aesthetics to the knitted material. Elastane and stretch polyester can each provide the knitted component with desired stretch and recovery properties. Rayon can provide a high shine and moisture wicking material, wool can provide a material with enhanced moisture wicking, nylon can provide a durable material with abrasion resistance, and polyester can provide a durable material with hydrophobic properties.

[0026] Other aspects of the knitted component can also be varied to affect the properties of the knitted component and provide desired attributes. For example, the yarns forming the knitted component can include monofilament or multifilament yarns, or the yarns can include filaments each formed of two or more different materials. Additionally, the knitted component can be formed using a particular knitting process to impart specific properties to regions of the knitted component. Thus, both the materials forming the yarns and other aspects of the yarns can be selected to impart different properties to specific regions of the upper 102.

[0027] In some embodiments, the elasticity of the knit structure can be measured based on a comparison of the width or length of the knit structure in a first unstretched state to the width or length of the knit structure in a second stretched state after a lateral force is applied to the knit structure. In further embodiments, the upper 102 can also include additional structural elements. For example, in some embodiments, a heel plate or cover (not shown) can be provided in the heel region 112 to provide additional support to the heel of the user. In some cases, other elements, such as plastic materials, logos, trademarks, etc., can be applied and secured to the exterior surface using adhesives or a thermoforming process. In some embodiments, properties associated with the upper 102, such as stitch types, thread types, or properties associated with different stitch types or thread types, such as stretch, aesthetics, thickness, breathability, waterproofness, or scuff resistance, can be varied. In some embodiments, the upper 102 is comprised of various layers that are heat pressed together to bond the various layers of the upper 102. For example, the layers that make up the upper 102 can be heat pressed at a single temperature at one time. The materials that make up the upper 102 may include an inner mesh layer, a thermoplastic polyurethane (TPU) film, and an outer mesh layer. In some embodiments, a TPU skin may be applied along the outer surface of the upper.

[0028] Referring again to FIG. 1 , the sole structure 104 is connected or secured to the upper 102 and extends between the user's foot and the ground when the footwear 100 is worn by the user. The sole structure 104 may include one or more components, which may include an outsole, a midsole, a heel, a toe cap, and / or an insole. For example, in some embodiments, the sole structure may include an outsole that provides traction to the user and structural integrity to the sole structure, a midsole that provides a cushioning system, and an insole that supports the user's arch. Additionally, the insole may be a strobel board, a forefoot board, a lasting board, or the like, that is attached to the upper by a strobel stitch, or a combination thereof, and the insole may be provided between the upper 102 and the sole structure 104, or the insole may be provided as part of the upper 102.

[0029] Additionally, an insole may be disposed within the interior cavity 106 of the upper 102 and may be in direct contact with the user's foot while the footwear 100 is being worn. Additionally, the upper 102 may also include a liner (not shown) that may enhance comfort, for example, by reducing friction between the user's foot and the upper 102, sole 104, insole, etc., and / or by providing moisture wicking properties. The liner may cover the entire interior cavity 106 or only a portion of it. In some embodiments, a bond (not shown) may surround the opening of the interior cavity 106 to secure the liner to the upper 102 and / or to provide an aesthetic element to the footwear 100.

[0030] 2 and 3, the footwear 100 also defines an outer surface 116 and an inner surface 118. The outer surface 116 corresponds to an outwardly facing portion of the footwear 100 while the footwear is worn by a user, while the inner surface 118 corresponds to an inwardly facing portion of the footwear 100. Thus, the footwear 100 has opposing outer and inner surfaces 116 and 118. The inner and outer surfaces 118 and 116 are adjacent to one another along a longitudinal center plane or axis 120 of the footwear 100, which is coplanar with the longitudinal axis L of FIG. 1. As discussed further herein, the longitudinal center plane or axis 120 may define a center, mid-axis between the inner and outer surfaces 118 and 116 of the footwear 100. In other words, the longitudinal plane or axis 120 extends between a rear proximal end 122 of the footwear 100 and a front distal end 124 of the footwear 100 and can continuously define the middle of the insole 126, sole structure 104, and / or upper 102 of the footwear 100, i.e., the longitudinal plane or axis 120 is a linear axis extending through the rear proximal end 122 of the heel region 112 to the front distal end 124 of the forefoot region 108.

[0031] Unless otherwise specified and without reference to Figures 2 and 3, footwear 100 may be defined by a forefoot region 108, a midregion 110, and a heel region 112. Forefoot region 108 may generally correspond to a portion of footwear 100 that encases a portion of foot 128 including one or more of toes or phalanges 130, ball of foot 132, and joints 134 connecting metatarsals 136 of foot 128 to toes or phalanges 130. Midregion 110 is proximate and adjacent to forefoot region 108. Midregion 110 generally corresponds to a portion of footwear 100 that encases the arch of foot 128 along with the bridge of foot 128. Heel region 112 is proximate and adjacent to midregion 110. Heel region 112 generally corresponds to that portion of footwear 100 that wraps around the rear of foot 128, including the heel or calcaneus 138, the ankle (not shown), and / or the Achilles tendon (not shown).

[0032] 2 and 3, the forefoot region 108, the central region 110, the heel region 112, the medial surface 118, and the lateral surface 116 are intended to define boundaries or regions of the footwear 100. To that end, the forefoot region 108, the central region 110, the heel region 112, the medial surface 118, and the lateral surface 116 generally characterize sections of the footwear 100. Certain aspects of the present disclosure may refer to portions or elements coextensive with one or more of the forefoot region 108, the central region 110, the heel region 112, the medial surface 118, and / or the lateral surface 116. Additionally, both the upper 102 and the sole structure 104 may be characterized as having portions along the forefoot region 108, the central region 110, the heel region 112, and / or the medial surface 118 and / or the lateral surface 116. Thus, the upper 102 and sole structure 104, and / or individual portions of the upper 102 and sole structure 104, may include portions located along the forefoot region 108, the midregion 110, the heel region 112, and / or the medial surface 118 and / or the lateral surface 116.

[0033] 2 and 3, the forefoot region 108, the central region 110, the heel region 112, the medial surface 118, and the lateral surface 116 are shown in detail. The forefoot region 108 extends from a toe end 140 to a widest portion 142 of the footwear 100. The widest portion 142 is defined or measured along a first line 144 that is perpendicular to the longitudinal axis 120 and extends from a distal end of the toe end 140 to a distal end of a heel end 146 opposite the toe end 140. The central region 110 extends from the widest portion 142 to a narrowest portion 148 of the footwear 100. The narrowest portion 148 of the footwear 100 is defined as the thinnest portion of the footwear 100 measured across a second line 150 that is perpendicular to the longitudinal axis 120. Heel region 112 extends from narrowest portion 148 to a heel end 146 of footwear 100 .

[0034] Numerous variations will be apparent to those skilled in the art from the foregoing description, and it should be understood that individual components thereof may be incorporated into numerous articles of footwear. Accordingly, it should be understood that aspects of footwear 100 and its components may be described with reference to general areas or portions of footwear 100, as described herein, and boundaries of forefoot region 108, central region 110, heel region 112, medial surface 118, and / or lateral surface 116, but may vary between articles of footwear. However, aspects of footwear 100 and its individual components may also be described with reference to precise areas or portions of footwear 100, and the appended claims herein may incorporate limitations related to these boundaries of forefoot region 108, central region 110, heel region 112, medial surface 118, and / or lateral surface 116, as described herein.

[0035] 2 and 3, the medial side 118 begins at the distal toe end 140 and bows outwardly along the medial side of the footwear 100 along the forefoot region 108 toward the central region 110. The medial side 118 reaches a first line 144 where the medial side 118 bows inwardly toward the central longitudinal axis 120. The medial side 118 extends from the first line 144, or widest portion 142, toward a second line 150, or narrowest portion 148, where the medial side 118 crosses the first line 144 or into the central region 110. When the second line 150 is reached, the medial side 118 bows outwardly away from the central longitudinal axis 120 where the medial side 118 crosses the second line 150 or into the heel region 112. The medial surface 118 then curves outwardly and then inwardly towards the heel end 146 , terminating at a point where the medial surface 118 meets the central longitudinal axis 120 .

[0036] The lateral surface 116 also curves outwardly along the lateral side of the footwear 100, beginning at the distal toe end 140, along the forefoot region 108, and toward the central region 110. The lateral surface 116 curves inwardly toward the central longitudinal axis 120 where it reaches a first line 144. The lateral surface 116 extends from the first line 144, or widest portion 142, toward a second line 150, or narrowest portion 148, where it crosses the first line 144, and enters the central region 110. Upon reaching the second line 150, the lateral surface 116 curves outwardly away from the central longitudinal axis 120, where it extends into the heel region 112, or crosses the second line 150. The lateral surface 116 then curves outwardly and then inwardly towards the heel end 146 , terminating at a point where the lateral surface 116 meets the central longitudinal axis 120 .

[0037] 2 and 3, the upper 102 extends along a lateral side 116 and a medial side 118 across the forefoot region 108, the midregion 110, and the heel region 112 to accommodate and encase the user's foot. When fully assembled, the upper 102 also includes an inner surface 162 and an outer surface 164. The inner surface 162 faces inwardly and generally defines the interior cavity 106, and the outer surface 164 of the upper 102 faces outwardly and generally defines the periphery or boundary of the upper 102. The upper 102 also includes an opening 166 at least partially disposed in the heel region 112 of the footwear 100, which allows access to the interior cavity 106 through which the foot can be inserted or removed. In some embodiments, the upper 102 can also include an instep region 168 that extends from the opening 166 in the heel region 112 across an area corresponding to the instep of the foot to an area proximate the forefoot region 108. The upper region 168 can define an area similar to the area in which the tongue 170 of this embodiment is located. In some embodiments, the upper 102 does not include the tongue 170, i.e., the upper 102 is tongue-less.

[0038] With reference to FIG. 1 , the sole structure 104 includes a midsole 172 and an outsole 174. In one embodiment, the outsole can be defined as the portion of the sole 104 that at least partially contacts the outer surface, e.g., the ground, when the footwear 100 is worn. The outsole 174 can define a bottom end or surface 176 of the sole structure 104 across the heel region 112, the mid region 110, and the forefoot region 108. Additionally, the outsole 174 can include a ground engaging portion or surface of the sole structure 104 and oppose its insole. As shown in FIG. 1 , the bottom surface 176 of the outsole 174 can include a tread pattern 178 that can include a variety of shapes and configurations. The outsole 174 can be formed from one or more materials to impart durability, wear resistance, abrasion resistance, or traction to the sole structure 104. In some embodiments, outsole 174 may be formed from any type of elastomeric material, such as rubber, including thermoset or thermoplastic elastomers, or a thermoplastic material, such as thermoplastic polyurethane (TPU). In some embodiments, outsole 174 may define a Shore A hardness of up to 95. Additionally, outsole 174 may be manufactured by processes including injection molding, vulcanization, layer-by-layer printing, i.e., additive manufacturing systems or methods, and the like.

[0039] 1 , the midsole 172 extends from the outsole 174 toward the upper 102 or extends between and connects the outsole 174 and the upper 102, and can be defined as at least a portion of the sole 104. The midsole 172 may be individually constructed from a thermoplastic material, such as polyurethane (PU), and / or ethylene vinyl acetate (EVA), its copolymers, or similar types of materials. In other embodiments, the midsole 172 may be constructed from an EVA-Solid-Sponge ("ESS") material, EVA foam (e.g., PUMA® ProFoam Lite TM, IGNITE foam), polyurethane, polyether, olefin block copolymer, organosheet, thermoplastic material (e.g., thermoplastic polyurethane, thermoplastic elastomer, thermoplastic polyolefin, etc.), or supercritical foam. The midsole 172 may be a single polymeric material or a blend of materials such as EVA copolymer, thermoplastic polyurethane, polyether block amide (PEBA) copolymer, and / or olefin block copolymer. An example of a PEBA material is PEBAX®. In some embodiments, the midsole 172 is manufactured by a process including injection molding, vulcanization, layer-by-layer printing, i.e., additive manufacturing systems or methods, and the like.

[0040] In embodiments in which the midsole 172 is formed from a supercritical foam process, the supercritical foam may be comprised of a microporous or particulate foam, such as TPU, EVA, PEBAX®, or mixtures thereof, produced using a process carried out in an autoclave, injection molding apparatus, or a vessel sufficiently heated / pressurized that can handle the mixing of a supercritical fluid (e.g., CO2, N2, or mixtures thereof) with a material (e.g., TPU, EVA, polyolefin elastomer, or mixtures thereof) that is preferably molten. In an exemplary process, a solution of supercritical fluid and molten material is pumped into a pressurized vessel, after which the pressure in the vessel is released, causing the molecules of the supercritical fluid to rapidly convert to a gas forming small pockets within the material, causing the material to expand into a foam. In further embodiments, the midsole 172 can be formed using alternative methods known in the art, including the use of an expansion press, an injection molding machine, a pellet expansion process, a cold foaming process, compression molding techniques, die-cutting, or any combination thereof. For example, the midsole 172 may be formed using a process that includes an initial foaming process using a supercritical gas to expand a material, followed by compression molding or die-cutting to a particular shape.

[0041] Returning to FIG. 2 , the footwear 100 also includes a fastening system 180 including laces 184 and a number of eyelets 188. In this embodiment, the laces 184 extend through the number of eyelets 188. In some embodiments, the fastening system 180 may include an elastic band. The fastening system 180 allows a user to change the dimensions of the upper 102, for example, to tighten or loosen a portion of the upper 102 and / or sole 104 around the foot as desired by the wearer. The fastening system 180 may also include a band (not shown) including one or more loops along the center of the upper 102 through which the laces 184 may be guided. In other embodiments, the fastening system 180 may be a hook-and-loop system such as Velcro®. For example, in some embodiments, the fastening system 180 may include one or more hook-and-loop straps. In yet other embodiments, the fastening system 180 may be any other laceless fastening system known in the art. In still other embodiments, the tightening system 180 may include another manual lacing system, a rotary closure device, or an automatic lacing system, such as the lacing systems described in U.S. patent application Ser. No. 15 / 780,368, filed May 31, 2018, and U.S. patent application Ser. No. 16 / 392,470, filed April 23, 2019, both of which are incorporated by reference in their entireties herein.

[0042] The present disclosure provides plates that are manufactured using additive manufacturing processes (e.g., printed layer by layer). The additive manufacturing process incorporates user metrics collected from various sources (e.g., pressure heat map information, laser scanners, force plates, user preferences, etc.), and continuous fiber manufacturing (CFF) manufacturing techniques to optimize the plate for a specific user's performance preferences for propulsion, stability, and comfort, etc. Additive manufacturing allows the plate to be manufactured with minimal waste compared to traditional subtractive manufacturing processes (e.g., injection molding, milling, grinding, etc.). Furthermore, additive manufacturing allows the plate to be manufactured with fewer processes and repetitive operations, avoiding the excessive labor typically required for customized, unique designs according to specific user preferences. Furthermore, CFF manufacturing techniques allow the plate to be manufactured efficiently and inexpensively while still using expensive high-performance materials such as carbon fiber, fiberglass, and Kevlar®. Additive manufacturing minimizes material and time waste as material is added in an iterative process to build the plate as designed. This is especially important when considering the costs associated with expensive materials like carbon fiber and Kevlar®, as well as the availability of supplies and / or shipments of such materials as needed. Eliminating waste allows users to source materials in more precise quantities and with greater predictability, while also reducing transportation costs and the emissions and pollution associated with shipping expensive materials long distances, e.g., globally.

[0043] Additive manufacturing using CFF is preferred for the manufacture of plates according to the present disclosure. The additive manufacturing process can be carried out using a 3D printer, such as a printer manufactured by MarkForged®, that can receive a design model and generate print instructions for 3D printing the plate. The design model can be an electronic three-dimensional representation of the plate that is intended to be formed for the footwear molding. In some embodiments, the design model can be a 3D CAD file, a 3D stereolithography file (.STL file), or an Eiger file provided by MarkForged®. TM The file may be in the form of any file compatible with web-based or cloud-based design programs such as Adobe Illustrator, ...

[0044] Alternatively or additionally, the design model may be generated by the controller in response to input data. For example, the physical characteristics collected and input into the software and used to design and generate the design model may include the end user's weight, the end user's gait, and / or the end user's foot pressure maps measured during standing, walking, cutting, and / or running. Additionally, various measurements of the foot may be recorded to determine appropriate dimensions of the plate and other aspects of the footwear, and data related to the foot gait may be obtained to determine whether the foot orientation indicates toe-strike or heel-strike, among other scenarios. The foot measurements and data may be used to determine optimal shape and performance characteristics of the plate, as well as optimal location of the plate within the footwear. Additionally, the collected measurements and data may be used to select materials to construct the plate. Additionally, the additive manufacturing process described herein may allow the stiffness of the plate to be tailored for a particular wearer based on the collected measurements and data. In another example, the plate may be manufactured in increments of stiffness to provide semi-custom footwear for individual wearers to select the appropriate composition.

[0045] Various alternative additive manufacturing methods that can be used to manufacture the plates of the footwear articles according to the present disclosure include binder jetting, direct energy deposition, selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting, laser powered bed fusion (LPBF), ultrasonic additive manufacturing, material extrusion, material jetting, joule printing, electrochemical deposition, cold spray metal printing, DLP metal printing, ultrasonic consolidation or ultrasonic additive manufacturing (UAM), LENS laser-based printing, liquid bath photopolymerization, sheet lamination, or electron beam freeform fabrication (EBF3).

[0046] As used herein, the term "stiffness" refers to the manner in which a component resists deformation when a load is applied. In particular, "stiffness" is described herein in terms of elastic deformation, i.e., temporary deformation that is considered non-destructive. Thus, "stiffness" may be used in conjunction with the terms "resistance" and "strength." Additionally, "stiffness" may be described herein in terms of various directions, types of deformation, material properties, and the like. For example, the "stiffness" of a component may be decomposed into bending stiffness, tensile stiffness, or shear stiffness. Additionally, the "stiffness" of a component is correlated to the modulus of elasticity (E) of the material used, where the modulus of elasticity can be quantified by the Young's modulus equation E=σ / ε, where σ is the uniaxial stress, i.e., force per unit surface, and ε is the strain, i.e., proportional deformation. For clarity, herein, "stiffness" may be further specified to refer to a particular type of resistance, such as bending resistance BR or torsional resistance TR. For clarity, herein, "stiffness" may be further defined to refer to a particular type of resistance, such as bending resistance BR or torsional resistance TR. In some cases, the "stiffness" of a component may be quantified or calculated in terms of dimensions, mass, or volume. For example, the "stiffness" of a component may be measured in units of Newtons per millimeter (N / mm) or units of Gigapascals (GPa), although other units may be used. Additionally, "stiffness" may be understood in relation to various aspects of footwear, such as comfort, support, stability, rigidity, durability, etc., while also being referred to qualitatively as being high or low.

[0047] 4 illustrates an exploded view of footwear 100 including a plate 200 according to one embodiment of the disclosure. Plate 200 includes a top surface 204 opposite a bottom surface 208, a rear segment 212, an arch segment 216, and a front segment 220. Rear segment 212 may extend through at least the heel region 112 of footwear 100 when assembled thereto and may correspond to a portion of plate 200 located near a rear portion of the foot, as previously described herein. Arch segment 216 of plate 200 is proximate and adjacent to rear segment 212 and corresponds to a portion of plate 200 located near a central region 110 of footwear 100 that encases the arch of the foot together with the foot bridge. The fore segment 220 of the plate 200 is closely adjacent to the arch segment 216 and corresponds to the portion of the plate 200 disposed near the forefoot region 108 of the footwear 100 that encases the toes, ball of the foot, and the joints connecting the metatarsals to the toes or phalanges. The plate 200 defines a longitudinal reference axis 224 that intersects the plate 200 at the heel end 146 and the toe end 140. The plate 200 also defines a centerline axis 228 that bisects the heel end 146 and the toe end 140 such that the reference axis 224 extends obliquely relative to the centerline axis 228.

[0048] In the illustrated embodiment, the plate 200 is embedded within the midsole 172, as indicated by the dashed exploded lines, showing its approximate location within the midsole 172. However, in some embodiments, the plate 200 may be fitted between the midsole 172 and the upper 102, or between the midsole 172 and the outsole 174, or the plate 200 may be configured as an outsole 174 that is attached to the upper 102, or the plate 200 may be included as part of the upper 102.

[0049] For clarity, directional coordinates X, Y, and Z are referenced in this disclosure. In particular, the X direction corresponds to a lateral to medial direction perpendicular to the longitudinal direction along which the longitudinal reference axis 224 extends, the Y direction corresponds to a longitudinal direction parallel to the longitudinal reference axis 224, and the Z direction corresponds to a vertical direction perpendicular to the X and Y directions. Additionally, the term "in-plane" is used herein to refer to a two-dimensional plane extending in the X and Y directions, with the Z direction being perpendicular. Additionally, it will be appreciated that the longitudinal reference axis 224 also defines a longitudinal reference plane extending perpendicular to the Z direction. With reference to FIGS. 1 and 4, it will be appreciated that the longitudinal plane defined by the longitudinal axis L may be coplanar with an in-plane direction or portion of the footwear 100. Additionally, the longitudinal plane defined by the longitudinal axis V may extend in the Z direction and be generally perpendicular to the in-plane direction and the longitudinal plane.

[0050] The plate 200 defines a perimeter 232 that curves outwardly relative to the centerline axis 228 from the heel end 146 toward the lateral side 116 in the heel region 112 to at least partially define the posterior segment 212. The perimeter 232 extends further along the lateral side 116 toward the central region 110 and curves inwardly relative to the centerline axis 228 to at least partially define the arch segment 216. The perimeter 232 further extends into the forefoot region 108 and curves outwardly before curving inwardly toward the toe end 140 to at least partially define the anterior segment 220. Similarly, the perimeter 232 curves outwardly from the heel end 146 toward the medial side 118 in the heel region 112 to at least partially define the posterior segment 212. The perimeter extends further along the medial side toward the central region and curves inwardly to at least partially define the arch segment 216. Additionally, the perimeter 232 extends into the forefoot region 108, curves outward, and then curves inward toward the toe end 140 to at least partially define the anterior segment 220. Thus, the perimeter 232 extends continuously throughout the plate 200 from the posterior segment 212 to the anterior segment 220 and vice versa, and from the lateral surface 116 to the medial surface 118 and vice versa. In some embodiments, multiple perimeter elements 236 (see FIG. 5A ) may be disposed along a portion of the perimeter 232 or along the entire perimeter 232. In other embodiments, the plate 200 does not include any perimeter elements 236 along the perimeter 232.

[0051] However, in certain embodiments, the plate 200 may be formed from an additive manufacturing process in which various layers of the plate 200 are printed in a printing process, such as any of the additive manufacturing processes described above. With reference to FIG. 5A, the plate 200 includes a plurality of composite layers 240a-g arranged sequentially in a vertical stack between the top surface 204 and the bottom surface 208. Throughout this disclosure, the plurality of composite layers 240a-g may be referred to collectively and individually as composite layers 240, and further as reinforcing layers. Each of the composite layers 240 extends continuously from the inner surface 118 to the outer surface 116, and from the rear segment 212 to the front segment 220. However, in other embodiments, some of the composite layers 240 may be discontinuous between the inner surface 118 and the outer surface 116, discontinuous between the rear segment 212 and the front segment 220, or a combination thereof.

[0052] In FIG. 5A, plate 200 is depicted as including seven composite layers 240a-g. However, plate 200 may include more or fewer composite layers than shown. In some embodiments, plate 200 includes only three composite layers, while in other embodiments, plate 200 includes 100 composite layers or 1000 composite layers or more. Additionally, in some embodiments, plate 200 is comprised of thousands of composite layers in certain portions or regions, while other portions or regions of plate 200 have fewer composite layers. In the illustrated embodiment, vertical plane V is centered between outer surface 116 and inner surface 118 of plate 200, and horizontal plane H is perpendicular to vertical plane V and is tangential to or coplanar with a portion of bottom surface 208 of plate 200. In this particular example, plate 200 has a shape in which top surface 204 of plate 200 is curved relative to a horizontal plane H between inner surface 118 and outer surface 116, and composite plies 240 each have different curvatures between inner surface 118 and outer surface 116, which curvatures may differ from each other and from the curvature of top surface 204. Additionally, bottom surface 208 defines a curvature that varies relative to the horizontal plane H between outer surface 116 and inner surface 118. Periphery 232 of plate 200 is also curved along outer surface 116 and inner surface 118.

[0053] 5A, the plate 200 includes at least a substrate or substrate material 244 and fibers or fiber material 248. It will be appreciated that the substrate material 244 may be referred to herein as a filler substrate, or matrix. It will be further appreciated that the fibers 248 may be referred to herein as fiber strands, filaments, or threads. The plate 200 includes composite layers 240a-g having properties and / or compositions that differ from each other or from at least adjacent composite layers 240a-g. To that end, each composite layer 240a-g of the plate 200 has various measurable properties including a volume VL of the layer, a substrate fraction SPL of the VL, a fiber fraction FPL of the VL, a fiber orientation or steering direction FOL of the layer, an axial effective modulus EAL of the layer, a transverse effective modulus ETL of the layer, and a thickness TL of the layer. Additionally, the plate 200 has various measurable properties including a total volume VT, a total substrate fraction SPT, a total fiber fraction FPT, a total effective fiber orientation or steering direction FOT, a total effective axial modulus EAT, a total effective transverse modulus ETT, and a total thickness TT.

[0054] In some embodiments, plate 200 may be formed from a composite or one or more layers of fibers, such as carbon fiber, aramid fiber, e.g., Kevlar®, boron fiber, glass fiber, natural fiber, and polymer fiber, or combinations thereof. In these embodiments, the fibers may be affixed or glued to a substrate of, e.g., nylon, epoxy, or plastic material, such as ultra-high molecular weight polyethylene (UHMWPE), or a fibrous material or composite material, among other suitable materials. In some embodiments, fibrous material 248 is fused to substrate 248 by heat and pressure during an additive manufacturing process. In other embodiments, fibrous material 248 is sewn, embroidered, glued, cemented, woven, stapled, or otherwise attached to substrate material 244 and / or fibrous material 248. In some embodiments, plate 200 may be formed from a unidirectional tape including carbon fiber, aramid fiber, such as Kevlar®, boron fiber, glass fiber, polymer fiber, or any other material with high strength-to-weight properties.

[0055] In the illustrated embodiment, each of the composite layers 240a-g differs in at least one measurable property from an adjacent composite layer 240a-g, as indicated by the different hatching used to represent each composite layer 240a-g. In some embodiments, one or more of the composite layers 240a-g are identical but are separated by one or more intervening composite layers 240a-g having different measurable properties. As shown in FIG. 5A, the bottom surface 208 may be defined entirely by one composite layer 240g, while in other embodiments, the bottom surface 208 may be defined by portions of two or more composite layers 240. Similarly, the top surface 204 may be defined entirely by one composite layer 240a, or alternatively, may be defined by portions of two or more composite layers 240. Additionally, each composite layer 240a-g may be exposed to the exterior surface 116 and the interior surface 118, although in some embodiments, one or more of the composite layers 240a-g may be hidden or recessed relative to the interior surface 118 and / or the exterior surface 116. Additionally, the composite layers 240a-g may be interrupted by voids (not shown) that intersect or separate one or more of the composite layers 240a-g. The plate 200 may be manufactured as a complementary arrangement or structure having voids (not shown) and the composite layers 240, allowing for complementary behavior, i.e., increasing in lateral dimensions when stretched longitudinally, or vice versa. Additionally, the plate 200 may be manufactured with channels (not shown) that allow air flow through portions of the plate 200.

[0056] In the illustrated embodiment of FIG. 5B, the plate 200 is embedded within the sole 104 of the footwear 100, and more specifically, the plate 200 is embedded within the midsole 172 of the sole 104. Additionally, the upper 102 includes the insole 126 in a Strobel arrangement such that the insole 126 is spaced apart from the plate 200 and does not directly contact the plate 200. In some embodiments, the plate 200 can be embedded within the midsole 172 in a manner that allows a portion of the plate 200 to contact the insole 126 or the upper 102. Additionally, in some embodiments, a portion of the plate 200 can be in contact with the outsole 174. In other embodiments, the plate 200 can be provided as part of the upper 102. For example, the plate 200 can be included as part of the insole 126 or can be inserted into the cavity 106 of the footwear 100 similar to a conventional orthotic insert. In some embodiments, plate 200 may comprise the entire sole structure 104 of footwear 100 , or footwear 100 may include only upper 102 and plate 200 .

[0057] 5A and 5B, the plate 200 is generally curved between the medial surface 118 and the lateral surface 116, and is also curved relative to the surrounding components of the footwear 100. For example, the plate 200 is curved downward toward the horizontal plane H between the lateral surface 116 and the vertical plane V, and is curved upward away from the horizontal plane H between the vertical plane V and the medial surface 118, such that the plate 200 is curved convexly relative to the horizontal plane H. In FIG. 5B, the horizontal plane H is tangent to the outsole 174, so the plate 200 is also curved convexly relative to the outsole 174. However, the plate 200 is curved concavely relative to the upper 102, such that the plate 200 is curved farthest away from the upper 102 near the vertical plane V and closest to the upper 102 at the medial surface 118 and the lateral surface 116. Additionally, while the insole 126 and the plate 200 are depicted as having generally similar curvatures in the footwear 100 of FIG. 5B, other configurations are possible. Additionally, the midsole 172 at least partially surrounds the plate 200 and, as shown, defines a curvature that varies above and below the plate 200, different from the curvature of the plate 200. In the illustrated embodiment, the insole 126, the midsole 172, the plate 200, and the outsole 174 are all mated to match each other's curvatures, such that no voids or gaps are disposed therebetween. However, it will be understood that a void or gap may be formed between one of the insole 126, the midsole 172, the plate 200, and the outsole 174 such that the curvature of the insole 126 does not match the curvature of the midsole 172.

[0058] Additionally, the plate 200 may be preloaded or deformed when assembled to the footwear 100. To that end, the curvature of the plate 200 may be altered or reduced during assembly within the sole 104 of the footwear 100 to match the curvature of the midsole 172 or the outsole 174 or the insole 126. Comparing FIG. 5A with FIG. 5B, for example, assembly with the sole 104 of the footwear 100 of FIG. 5B may cause the curvature of the bottom surface 208 of the plate 200 to deform, e.g., invert from a concave to a convex curvature. As a result, the plate 200 may deform upon interaction with the sole 104, generating stresses that may change or affect properties, e.g., stiffness and propulsion, in one or more directions during use. Such stresses generated by assembly with the footwear 100, combined with the tuned stiffness and shape of the plate 200, may provide responsive benefits that enhance the customizability of the plate 200 within the footwear 100. As used herein, the term "responsiveness" may refer to the sensitivity of the plate 200 to applied loads, i.e., external forces applied during use, whether the applied loads are due to the user's body weight or due to activities such as running, walking, jumping, turning, lifting, etc., and may also refer to the sensitivity of the plate 200 to deformation in one or more directions. In some embodiments, the responsiveness of the plate 200 may be varied along the anterior segment 220, the arch segment 216, and the posterior segment 212, and the responsiveness may be varied between the lateral surface 116 and the medial surface 118. In some implementations, the arch segment 216 of the plate 200 may be preloaded to increase the responsiveness, making the plate 200 more sensitive to walking activities where a smaller amount of deformation is experienced, while providing the user with the benefit of increased propulsion and support. In some embodiments, the anterior segment 220 may be provided with increased responsiveness to provide maximum propulsion when the user steps out during a jumping activity.

[0059] In some embodiments, the plate 200 is positioned diagonally between the upper 102 and the outsole 174 such that the front segment 220 is farther away from the upper 102 than the rear segment 212. In this manner, the rear segment 212 is positioned vertically higher, i.e., higher in the Z direction, relative to the front segment 220 and / or the arch segment 216. In this manner, the plate 200 can be positioned to promote propulsion or spring-back during use. Additionally, the plate 200 can be formed with different shapes and different curvatures along the reference axis 224 and / or between the medial surface 118 and the lateral surface 116 to promote cushioning, propulsion, and support during use.

[0060] In some embodiments, the fibrous material 248 of the plate 200 may have a tensile stiffness defined at least in part by a tensile modulus measured according to a test method defined by test standard ASTM D4018 or an equivalent standard. For example, in certain embodiments, the fibrous material 248 of the plate 200 may have a tensile modulus of at least 70 GPa, or at least about 85 GPa, or at least about 200 GPa, or at least about 300 GPa. In further embodiments, the fibrous material 248 has a tensile modulus between about 300 GPa and about 400 GPa. Thus, the fibrous material 248 may have a tensile strength, i.e., a stress defined by the amount of load per unit area, of about 500 megapascals (MPa) to about 800 MPa, measured according to a test method defined by test standard ASTM 3039 or an equivalent standard. Additionally, the fibrous material 248 of the plate 200 may have a flexural stiffness defined at least in part by a flexural modulus measured according to a test method defined by test standard ASTM D790 or C651 or an equivalent standard. For example, the fiber material 248 can have a flexural modulus of at least about 22 GPa, or at least about 50 GPa, or at least about 100 GPa, or at least about 200 GPa. In further embodiments, the fiber material 248 has a flexural modulus between about 50 GPa and about 200 GPa. Thus, the fiber material 248 can have a flexural strength, i.e., stress defined by the amount of load per unit area, between about 200 MPa and about 600 MPa, measured according to the test method defined by test standard ASTM D790 or an equivalent standard. Additionally, the fiber material 248 of the plate 200 can have a flexural modulus of at least about 1.2 g / cm 3 and about 2.0 g / cm 3 The density may be between 0.01 and 0.1.

[0061] Additionally, the substrate material 244 of the plate 200 may have a tensile stiffness defined at least in part by a tensile modulus measured according to a test method defined by test standard ASTM D638 or equivalent. For example, in certain embodiments, the substrate material 244 may have a tensile modulus of at least about 1 GPa, or at least about 2 GPa, or at least about 4 GPa. Additionally, the substrate material 244 may have a flexural stiffness defined by a flexural modulus measured according to a test method defined by test standard ASTM D790, or equivalent. For example, the substrate material 244 may have a flexural modulus of at least about 1 GPa, or at least about 2 GPa, or at least about 3 GPa. In further embodiments, the substrate material 244 has a flexural modulus between about 1.4 GPa and about 3.7 GPa. Thus, the substrate material 244 may have a flexural strength, i.e., a stress defined by the amount of load per unit area, of about 50 MPa to about 90 MPa measured according to a test method defined by test standard ASTM D790 or equivalent. In another embodiment, the substrate material 244 of the plate 200 may have a heat deflection temperature measured according to a method defined in test standard ASTM D648 Method B or an equivalent standard. For example, the substrate material 244 may have a heat deflection temperature between about 41° C. and about 150° C. The substrate material 244 used to form the plate 200 may also have a heat deflection temperature of about 1 g / cm 3 and about 1.5 g / cm 3 The density may be between 0.01 and 0.1.

[0062] For reference, the tensile modulus of a steel or steel alloy, e.g., ASTM A36 steel, measured according to the test method defined by test standard ASTM E8 or an equivalent standard, is about 200 GPa, and such a steel has a modulus of elasticity of about 7.85 g / cm 3In some embodiments, the tensile modulus of the plate of the present disclosure is about 200 GPa, measured according to the test method defined by test standard ASTM E8 or equivalent. Thus, the plate 200 is configured to have a tensile modulus similar to steel, but a density that is less than 25% of the density of steel. Thus, the plate of the present disclosure has a strength-to-weight ratio that is substantially higher than that of steel for at least one directional strength property.

[0063] The composition of the plate 200 is substantially composed of the substrate material 244 and the fiber material 248 such that the sum of the substrate percentage SPT and the fiber percentage FPT is about 100% of the total volume TV of the plate 200. Thus, if the substrate percentage SPT is about 50%, the corresponding fiber percentage FPT is about 50%. Furthermore, since the fiber material 248 generally has a greater stiffness, including bending stiffness and tensile stiffness, than the substrate material 244, the stiffness of the plate 200 can be manipulated by controlling or selecting the composition of the plate 200. Therefore, by manufacturing the plate 200 using additive manufacturing methods, the volume and placement of materials can be precisely and efficiently selected, and the composition of the plate 200 can be selected according to the desired stiffness. In some embodiments, the plate 200 can have a substrate percentage SPT of about 75%, which corresponds to a fiber percentage FPT of about 25%, resulting in the plate 200 having generally more flexible and elastic properties. This may be desirable when user comfort is a priority. In other embodiments, plate 200 can have a fiber fraction of about 75%, which corresponds to a substrate fraction of about 25%, so that plate 200 generally has greater stiffness and strength characteristics. This may be desirable when propulsion and support are a priority. In some embodiments, substrate fraction SPT of plate 200 may range from about 25% to about 99%, and fiber fraction FPT of plate 200 may range from about 25% to about 99%.

[0064] In some embodiments, the plate 200 and its stiffness may be selected and designed for a particular user. For example, the stiffness of the plate 200 may be selected based on the particular muscle strength, tendon flexibility, or joint flexibility of the user. In further embodiments, the stiffness of the plate 200 may vary such that one portion of the plate 200 is stiffer compared to another portion of the plate 200. In some embodiments, the plate 200 is included within the sole 104 of the footwear 100. For example, the plate 200 may be embedded within the midsole 172, the outsole 174, or the insole 126. In other embodiments, the plate 200 may be positioned between the insole 126 and the midsole 172, or the plate 200 may be positioned between the midsole 172 and the outsole 174.

[0065] Generally, plates constructed of composite fiber materials, such as Kevlar®, carbon fiber, and fiberglass, have improved strength-to-weight ratios compared to plates made entirely without added metal, matrix, or fiber. However, composite fiber materials are strongest in tension, and this is limited to a particular direction, i.e., the axial direction in which the composite fiber material is pulled. Thus, a composite layer having fiber material oriented in a single uniaxial direction will be strongest in that direction, but will exhibit different, e.g., weaker, properties in other directions. In this manner, the composite layer is considered to be anisotropic, i.e., exhibit different strength properties in different directions.

[0066] Composite laminates or structures manufactured using continuous fiber fabrication (CFF) techniques may exhibit quasi-isotropic (QI) properties, e.g., properties that are substantially similar in most directions, due to the structure including multiple layers or plies with fiber arrays arranged at specific angles relative to a reference plane. In one embodiment, one or more layers are formed with fiber arrays arranged at 0 degrees relative to the reference plane, some other layers are formed with fiber arrays arranged at ±45 degrees relative to the reference plane, and still other layers are formed with fiber arrays arranged at 90 degrees relative to the reference plane. Additionally, anisotropically biased layers may be formed with fiber arrays arranged at 0 degrees, ±30 degrees, and 90 degrees. Composite laminates with QI properties, i.e., QI laminates, may have substantially isotropic properties in-plane, e.g., increased tensile strength or stiffness, similar to isotropic materials. Substantially QI laminates may include randomly oriented or oriented fibers or fiber arrays such that substantially equal strength is provided in all directions in a single plane. Typically, a QI laminate will include unidirectional plies, e.g., 3D printed plies, oriented at 0, 90, 45, and -45 degrees, with at least 12.5 percent of the plies oriented in each of these directions. QI properties can also be achieved with plies oriented at 0, 60, and 120 degrees.

[0067] It will be appreciated that the stiffness of the plate 200 and / or its composite layer 240 can be understood in terms of bending resistance BR and torsional resistance TR. Bending resistance BR is a mathematical relationship between lateral force and deflection, and bending resistance BR may be referred to herein as spring constant or stiffness. Similarly, torsional resistance TR is a mathematical relationship between torsional force and deflection, and torsional resistance TR may be referred to as rotational stiffness. It is well known that bending resistance BR and torsional resistance TR are proportional to the elastic modulus of a material or material configuration. Furthermore, the geometry and dimensions are also proportional to bending resistance BR and torsional resistance TR depending on the orientation and location of the applied load. For example, dimensions defined parallel to the direction of the applied load have a greater impact on the specific resistance, for example, when a bending load is applied in the Z direction and a thickness is defined in the Z direction.

[0068] The bending resistance BR and torsional resistance TR properties of each composite ply 240 are also related to its effective modulus, depending in part on the orientation of the load application. For loads applied axially in-plane, i.e., in the X and Y directions, the ply axial effective modulus EAL is of primary importance. For loads applied transversely, i.e., in the Z direction, which includes bending deformations, the ply transverse effective modulus ETL is of primary consideration. EAL is approximated using the formula EAL=EF×FPL+ES*SPL, where EF is the modulus of elasticity of the fiber material 248, FPL is the volume fraction of the fiber material 248, EM is the modulus of elasticity of the substrate material 244, and SPL is the volume fraction of the substrate material 244.

[0069] Also, the formula TIFF2025502977000002.tif1794 is used to approximate the ETL. Thus, as the fiber volume fraction FPL approaches a value of 1.0, i.e., as the fiber material 248 occupies a larger percentage of the volume VL of the composite layer 240, the ETL approaches the value of the elastic modulus EF of the fiber material 248, as shown in the graph provided in FIG. 6. Also, for the entire plate 200, the total effective elastic modulus in the axial EAT and the total effective elastic modulus in the transverse ETT can be approximated. To do this, the average values ​​of EAL and ETL of each composite layer 240 are calculated, but each value is weighted according to its relationship to the total volume TV of the plate 200 and the offset of the fiber orientation FOL with respect to the associated reference plane. Thus, composite layers 240 that include a larger percentage of the total volume TV of the plate 200 have a larger impact on the EAT and ETT of the plate 200. Also, composite layers 240 that are offset from the reference plane have a smaller impact on the EAT and ETT. This allows the bending resistance BR and torsional resistance TR of the plate 200 to be approximated.

[0070] Thus, the arrangement of the composite layer 240 with the fiber arrays arranged in various directions allows the plate 200 to exhibit QI properties, e.g., strength or resistance properties that are approximately equal in all directions. For example, when the plate 200 is provided in the sole 104 of the footwear 100, bending occurs due to a load applied in the Z direction and the tendency of the user to arch the heel off the ground and propel forward from the forefoot. This force is generally perpendicular to the in-plane directions in which the plate 200 and the fiber material 248 are arranged, i.e., the X and Y directions, and thus generally perpendicular to the direction in which the composite layer 240 is strongest. However, during such bending, the top surface 204 of the plate 200 is in compression and the bottom surface 208 is in tension as the downward force, i.e., the load, causes deformation of the plate 200 and footwear 100. Thus, the composite plies 240 disposed near the top surface 204 are subjected to a compressive force in the longitudinal or Y direction, and the composite plies 240 disposed near the bottom surface 208 of the plate 200 are subjected to a tensile force in the longitudinal or Y direction. Thus, to increase the bending resistance BR, the composite plies 240 disposed near the top surface 204 can be oriented such that the fibrous material 244 extends longitudinally, i.e., parallel to the direction in which the compressive force is applied, and the composite plies 240 disposed near the bottom surface 208 can be oriented such that the fibrous material 248 extends longitudinally, i.e., parallel to the direction in which the tension force is applied.

[0071] Additionally, it may be desirable to tailor the bending resistance BR and, relatedly, the thrust provided by the plate 200. To that end, the composite plies 240 may be arranged in various operating directions, i.e., in the direction in which the axial or orientation of the fibrous material 248 extends, which makes the composite plies strongest. The bending resistance BR of the composite plies 240 is greatest when the operating direction FOL is parallel to the longitudinal direction, and becomes less and less when the operating direction FOL is offset from the longitudinal direction toward an orthogonal direction, e.g., rotating. Thus, the bending resistance of the composite plies 240 is proportional to the degree to which the working direction FOL is offset from the bending direction. Additionally, the combination of composite plies 240 that make up the plate 200 is strongest when all of the operating directions FOL are oriented parallel to each other and parallel to the longitudinal direction. However, the stack of composite plies 240 that make up the plate 200 may be tailored to achieve the desired bending resistance BR by arranging some of the composite plies 240 in an operating direction that is offset from the longitudinal direction, which allows for greater deflection in response to an applied load, and subsequently also provides springback or thrust.

[0072] It is envisioned that the plate 200 can be manufactured using CFF technology to have localized portions or regions of different properties. For example, the rear segment 212 of the plate 200 can be manufactured to be stronger than the arch segment 216 and the anterior segment 220. To that end, the rear segment 212 can be constructed from composite plies 240 that each define greater EAL and ETL properties than the composite plies 240 in the arch segment 216 or the anterior segment 220. Additionally, the rear segment 212 of the plate 200 can include greater EAT and ETT than the arch segment 216 and the anterior segment 220. This is because the additive manufacturing process using CFF technology allows for a wide range of customization and control, such as, for example, depositing the fiber material 248 in various motion directions FOL, controlling the volume of the fiber material 248 within the portions and layers, and selecting various materials.

[0073] In some embodiments, the EAT and ETT can vary across the plate 200 and between the posterior segment 212, the arch segment 216, and the anterior segment 220, and between the lateral surface 116 and the medial surface 118. For example, the plate 200 can be designed to have a higher EAT and ETT than the arch segment 216 by manufacturing the anterior segment 220 to have a higher bending resistance BR in the anterior segment 220 than the arch segment 216, thereby increasing propulsion. The plate 200, and particularly the anterior segment 220, deforms during wear or use, for example, due to dorsiflexion and plantarflexion movements, particularly within the metatarsophalangeal joint (MTP) of the user's foot. It is well known that potential energy PE increases as the deformation, i.e. bending, of the structure increases, and potential energy PE is converted to kinetic energy KE as the structure returns to an undeformed state, similar to a spring. When the load is reduced or removed, the front segment 220 of the plate 200 bounces back to its undeformed state, converting potential energy PE into kinetic energy KE to generate a propulsive force PF between the ground and the user's foot. The speed at which the plate 200, and in particular the front segment 220, bounces back after deformation can be understood as a bending resistance BR, which is influenced by various properties of the plate 200, such as the specific EAT and ETT in the front segment 220. Thus, higher EAT and ETT increase the bending resistance BR and propulsive force PF provided by the front segment 220 of the plate 200. Without the plate 200, the footwear 100 and the MTP joints of the user's foot often absorb potential energy PE and thus convert less of the potential energy PE into potential energy KE during use. However, due to the plate 200 with increased stiffness, such as bending resistance BR and torsional resistance TR, more potential energy PE generated by the user is converted into kinetic energy KE and thus returned to the user.

[0074] With reference to FIG. 7, the plate 200 can be manufactured by a printer 300 configured to print a composite structure layer by layer. In the illustrated embodiment, the printer 300 includes a housing 304 including a print bed or platform 308 therein. The platform 308 is supported by supports 312 and operably engages with a vertical rail 316 that extends generally in the Z direction within the housing 304. The housing 304 further includes a lateral rail 320 that extends generally in the X direction and a longitudinal rail 324 that extends generally in the Y direction. The platform 308 can be translated vertically along the vertical rail 316 by operation of a drive or motor (not shown) housed within the housing 304. A preformed mold or block 328 is supported by the platform 308 within the housing 304.

[0075] As shown in FIG. 7, the printer 300 further includes a first head 332 and a second head 336 within the housing 304. In the illustrated embodiment, the first and second heads 332, 336 are arranged side-by-side, although other configurations are possible. Additionally, a scanner 340 is provided proximate to the first head 332, although the scanner 340 may be located elsewhere in the housing 304. In some embodiments, the scanner 340 is a laser scanner capable of detecting and measuring the dimensions and shape of an object on the platform 308, although other types of scanners may be used, such as 3D cameras, light detection and ranging (LIDAR) devices, and the like. In the illustrated embodiment, the first head 332 includes a first nozzle 344 and is associated with a first supply 348 located within the housing 304. Additionally, the second head 336 includes a second nozzle 352 and is associated with a second supply 356 located within the housing 304. The first nozzle 344 and the second nozzle 352 may each include a cutter (not shown) capable of chopping or severing the substrate material 244 and / or the fibrous material 248 during operation. However, in some embodiments, the cutter (not shown) is provided as a separate component separate from the first nozzle 344 and the second nozzle 352.

[0076] In the illustrated embodiment, the first supply 348 and the second supply 356 are provided as bobbins or spools each holding a particular material, and preferably the first and second supplies 348, 356 hold different materials. In the illustrated embodiment, the first supply 348 holds the substrate material 244 and the second supply 356 holds the fibrous material 248, although other configurations are contemplated. In other embodiments, the printer 300 can include three or more printer heads, or only one printer head. Additionally, in some embodiments, the printer 300 can include three or more supplies, or only one supply. In some embodiments, two or more supplies are associated with a single head, while in other embodiments, one supply serves two or more heads.

[0077] The first and second heads 332, 336 and the scanner 340 are operably coupled to the longitudinal rails 324 and the lateral rails 320 to form a housing 360 that can also be vertically translated within the housing 304. The first and second heads 332, 336 are configured to translate along the longitudinal rails 324 and the lateral rails 320 by drive motors (not shown), and the housing 360 can further be vertically translated within the housing 304 relative to the platform 308. In addition, the platform 308 can be vertically translated relative to the housing 360. Thus, the platform 308 and the housing 360, including the first and second heads 332, 336, are configured to be moved relative to one another by dedicated motors (not shown) to provide several degrees of freedom and range of movement for precise and convenient movement during the printing process.

[0078] 7, the first head 332 is configured to receive the substrate material 244 stored on the first supply 348 during a particular step or operation of the manufacturing. The first nozzle 344 is therefore configured to be compatible with the substrate material 244 such that the first head 332 is configured to be actuated to apply the substrate material 244 via the first nozzle 344 to components disposed on the platform 308. In addition, the second head 336 is configured to receive the fibrous material 248 stored on the second supply 356 during a particular step or operation of the manufacturing. The second nozzle 352 is therefore configured to be compatible with the fibrous material 248 such that the second head 336 is configured to be actuated to continuously apply the fibrous material 248 via the second nozzle 352 to components disposed on the platform 308. In some steps or operations, both the first head 332 and the second head 336 are activated simultaneously to apply the substrate material 244 and the fiber material 248, respectively, to components on the platform 308. In other steps or operations, only one of the first head 332 and the second head 336 is activated, while the other is deactivated to apply one of the substrate material 244 and the fiber material 248, respectively. The fiber material 248 may be deposited or applied for fusing to the substrate material 244 and / or to another strand or fiber material 248 during the printing process. Additionally, pressure may be applied using the second nozzle 352 to continuously compress and direct the fiber material 248 into a desired shape, for example, as the fiber material 248 is fused.

[0079] The printer 300 includes a controller (not shown) programmed to control the printing process based on a set of instructions, e.g., source code, corresponding to a design model of a 3D component such as the plate 200. In particular, the design model is generated using a software program, e.g., a browser-based or web-based software program, and aspects of the plate 200 and the printing process are predetermined for use in the printer 300. For example, the plate 200 can be specifically designed in the software according to certain inputs, e.g., foot size, dimensions, shape, contour, stiffness, etc., that are measured or collected using various sources, e.g., laser scanners, gait analysis, force profiles, images, medical records, and user preferences. Once the inputs are loaded into the software and, e.g., prioritized and considered among one another, the software can be used to optimize the design of the plate 200 to fit the user. In some cases, a technician trained to use the software and / or the printer 300 can assist the user in optimizing the plate 200 for performance and / or a particular use, such as a medical application. The software then generates the design model in a transferable format, e.g., a file, compatible with the printer 300. The design model is communicated to the printer 300 via an Internet connection, a Bluetooth® connection, a radio frequency connection, a USB or Ethernet cable, a digital storage disk, or any other medium suitable for communication between the software and the printer 300.

[0080] FIG. 8A shows a flow diagram of an exemplary method of designing and 3D printing a composite plate. In step S100, measurements and preferences are collected from various sources, such as those described above, and entered as input data into a software program for analysis. In some examples, the software program can automatically perform step S104 by analyzing the input data to automatically generate an optimized design model of the plate. In other examples, a technician or expert assists in performing step S104 by reviewing and modifying the input data to correct errors, inconsistencies, or unique customization preferences. In step S108, the software program generates a design model based on the input data provided. Thus, the design model is a first representation of a customized plate in which various attributes are presented to the user. One important attribute is the material and composition selected for the customized plate in the design model. In step S112, the software program can automatically recommend certain materials based on the input data, but the user can also manually select the materials to use. For example, some types of substrate materials 244 or fiber materials 248 are more expensive than others, so the user may wish to reduce the costs associated with the recommended materials.

[0081] In step S116, after the design model is generated and materials are selected, the software program is programmed to optimize the design model for 3D printing. Specifically, the software program analyzes various aspects of the design model to identify areas requiring further reinforcement, such as edges that may benefit from applying curvatures, e.g., fillets, or openings that may benefit from having additional fiber material 248 wrapped around them. The software program also generates warnings or notifications associated with areas having thicknesses below a minimum thickness threshold associated with the particular material, geometry, and composite ply 240 specified in the design model. If warnings and notifications remain unresolved, depending on the severity, the software program may not allow the user to proceed beyond step S116.

[0082] In step S120, a simulation may be run against the design model within the software program, but this step S120 is optional for the user and need not be performed. In some instances, it may be used to troubleshoot any outstanding warnings or notices before the simulation proceeds, or the user may compare simulation data between various material selections, or between various modifications to the input data. In step S124, the user may further modify or revise the input data and material selections, among other aspects, to generate a new design model and, if desired, a new simulation.

[0083] In step S128, the user prompts the software program to generate the design model in a transferable file format as described above. Additionally, printing instructions are generated by the software program for communication with the printer 300 or equivalent. In some embodiments, the printing instructions may be generated by a controller (not shown) of the printer 300 after receiving the digital model from the software program. The user may transfer or send a file containing the design model and printing instructions to the printer 300 by various communication methods as described above.

[0084] In step S132, the user activates the printer 300 to begin the printing process according to the design model and the printing instructions, including the sub-processes described in more detail below. After the printer 300 completes the printing process, the user removes the printed model of the plate 200 from the printer 300 (S136) and, if necessary, separates the printed model from the preform mold 328. The term "printed model" is used herein to indicate the plate 200 immediately after the completion of the printing process, and is also used to include the plate 200 and unfinished or unprocessed versions of the plate 200. In some examples, the user determines whether any treatment is necessary or desired, which is also described in more detail below. If necessary, the user proceeds to process the printed model of the plate 200 in step S140. Finally, once it is determined that the printed model of the plate 200 is in a finished state, the plate 200 can be placed in the desired location of the footwear 100.

[0085] FIG. 8B shows a flow diagram of an exemplary method of operating the printer 300, which relates to the sub-process of step S132 of FIG. 8A. In step S200, a start-up or warm-up process is initiated after the printer 300 is powered on. The warm-up process may take several minutes. Next, in S204, the user selects and places a first supply 348 having a desired substrate material 244, and the printer 300 supplies the substrate material 244 to the first head 332. Next, in step S208, the user selects and places a second supply 356 having a desired fiber material 248, and the printer 300 supplies the fiber material 248 to the second head 336. In process S212, the user selects an appropriate preformed mold 328 for the particular component to be printed, e.g., the printed model of the plate 200. Furthermore, the user places the preformed mold 328 in the appropriate orientation on the platform 308 in the printer 300. Next, in step S216, the user uses a software program to generate print processing instructions in a transferable file format and transmits them to the printer 300.

[0086] In step S220, the user considers characteristics associated with the printing process instructions, such as, for example, print duration, cycles, pauses and / or interruptions, material volume, etc., and determines when to start the printing process. The software program can provide a recommended optimal start time to avoid downtime. For example, the printing process may include an 8-hour cycle and a 2-hour cycle, and therefore, it may be optimal to start the printing process at the end of the workday, for example, at about 5 p.m., so that the 8-hour cycle can be completed overnight and the shorter 2-hour cycle can be completed the next day. In this way, the user can make the printer 300 available for shorter cycles during the workday, such as, for example, normal business hours, and also keep the printer 300 productive during non-working hours, such as, for example, overnight. After considering the characteristics of the printing process and recommendations provided by the software program, the user determines when to start the printer 300 and start the printing process.

[0087] Next, in step S224, the user initiates the printing process and attends the printer 300 as necessary. For example, the printing process may require the user to replenish the first supply 348 of the substrate material 244 or to replace the substrate material 244 with another type. Next, in step S228, after the printer 300 completes the printing process, the user may remove the printed model from the printer 300 and separate the preformed model from the printed model of the plate 200. To do so, various hand tools may be used, such as a screwdriver, a chisel, a hammer, etc. As shown in step S232, the user performs a quality inspection of the printed model of the plate 200 to identify any defects or risks. In one example, the quality inspection may include, for example, a simple visual inspection of the printed model of the plate 200 to identify any visible defects, such as cracks, improper voids or shapes, loose strand ends or loops, etc. In another example, the user may perform non-destructive testing on the printed model of the plate 200 to verify that the strength is satisfactory in each direction compared to the design data. The user may also measure the weight and / or volume of the printed model to verify its composition by comparing it to the design data. Other tests may be performed to identify any defects associated with the printed model and / or deviations from the design data.

[0088] In step S236, the user determines whether the defects identified from the quality inspection in step S232 pose a significant risk to the performance and / or quality of the printed model. If the user determines defects that present a significant risk, the user may determine whether those defects can be repaired by another process. Additionally, in step S240, the user may also determine whether the costs associated with the repair, e.g., time and materials, are economical before deciding whether to perform the repair. If the defects are determined to be repairable and economical, the user submits the printed model for such repair, which may include additional printing or treatment processes, as in step S244. If the defects are not repairable or are uneconomical in step S248, the printed model may be discarded in accordance with any relevant local regulations. If no defects exist, the user may proceed to step S252.

[0089] In step S252, the user determines whether the printed model should undergo any treatment process. Such treatment processes may include application of coatings, compression, sanding and / or polishing to modify the properties of the printed model, attachment of pins or rods to the printed model to aid in installation on the footwear 100, and other finishing techniques. In step S256, the user performs or arranges to perform any suitable treatment process that results in the printed model becoming a finished plate 200. After the treatment process is completed in step S260, the user performs a quality inspection again to identify any defects or risks. If defects are identified, the user again decides in step S268 whether to perform a repair. If it is worthwhile and economical in step S272, the repair is performed. After the repair is finished, the quality inspection in step S264 is performed again for a final check. If no defects are identified in the quality inspection in step S264, whether after repair or not, the user proceeds to step S276, where the plate 200 is installed or assembled in the footwear 100 in a completed state.

[0090] As part of steps S204 and S208, the user identifies the specific materials specified by the design model, namely, the substrate material 244 and the fiber material 248. In doing so, the user can consider the variable costs associated with the substrate material 244 and the fiber material 248. Generally, the fiber material 248 is more expensive and expensive than the substrate material 244, and in some cases, the fiber material 248 may be more rare or difficult to purchase in sufficient quantities. Thus, plates that use large amounts of the fiber material 248 are often more expensive and, in some cases, more sensitive to supply chain disruptions and resource fluctuations. Furthermore, conventional manufacturing methods involve material removal and therefore require larger amounts of excess material to account for such removal, e.g., cutting blanks from larger sheets of material. In contrast, additive manufacturing eliminates the need for such excess material. The optimized use of the fiber material 248 in the additive manufacturing methods of the present invention, such as the CFF technique, allows the user to achieve improved plate performance, e.g., increased customized stiffness, while minimizing costs. Thus, the additive manufacturing methods of the present invention can be optimized according to a variety of factors including cost, availability, and performance, among others.

[0091] The user then loads a first supply 348 and a second supply 356 containing the specified materials into the printer 300, and in particular, the user supplies a portion of the substrate material 244 from the first supply 348 to the first head 332 and a portion of the fibrous material 248 from the second supply 356 to the second head 336.

[0092] After the printer 300 is activated in step S224 to begin the printing process, the printer 300 operates according to instructions associated with the design model to selectively activate the first head 332 and the second head 336 to print the plate 200 layer by layer. In some examples, the printer 300 prints the plate 200 from bottom to top, such that the bottom surface 208 is printed before the top surface 204. In other examples, the geometry and / or aspects of the plate 200 are printed layer by layer in a reverse orientation, such that the top surface 204 is printed before the bottom surface 208. Thus, the printer 300 instructs the first head 332 and the second head 336 to print the composite layers 240 of the plate 200 in an optimized orientation and manner, as informed by the design model. Once the printing process is complete, the plate 200 is provided with an unfinished printed model consisting of composite layers 240 ranging from two to several thousand layers.

[0093] In process S256, the printed model can then be processed in a compression mold 370, such as a marriage mold, as described with respect to Figures 9A and 9B. Specifically, the printed model can be received in a negative mold 374 of a first block 378 corresponding to a particular shape and geometry, while a second block 382 is configured to operate with the first block 378 during the compression molding process. In some embodiments, the second block 382 includes a positive mold 386 extending therefrom and configured to protrude into the negative mold 374 of the first block 378 during the compression molding process. In other embodiments, the second block 382 includes a flat surface that encloses the printed model within the negative mold 374 of the first block 378.

[0094] During the compression molding process, the first block 378 and the second block 382 are compressed against each other with the printed model disposed therebetween. The magnitude of compression, i.e., the force of pressure measured in units of Newtons (N) or pounds per square inch (PSI), may vary over time throughout the compression molding process, or the magnitude of compression may remain constant throughout the compression molding process. In addition, heat may be applied to the printed model via the first block 378 and / or the second block 382, ​​or heat may be applied directly to the printed model. Heat may be applied for various times, at various temperatures, through various media, e.g., steam, glycol, hot water, hot air, or through a heat exchanger. In addition, cooling may be applied to the printed model via the first block 378 and / or the second block 382, ​​or cooling may be applied directly to the printed model. Cooling may be applied for various times, at various temperatures, through various media, e.g., glycol, cold water, cold air, or through a heat exchanger.

[0095] Additionally, the compression molding process may include the injection of a volume of resin, such as thermoplastic polyurethane (TPU), acrylonitrile butadiene styrene (ABS), epoxy, vinyl, nylon, polyetherimide (PEI), polyetheretherketone (PEEK), polylactic acid (PLA), or liquid crystal polymer, among others, to serve as a coating for the printed model. That is, the printed model may be coated with resin during the compression molding process. Various aspects of the compression molding process may be adjusted or modified to achieve specific coating characteristics or to accommodate specific resin materials. For example, thicker coatings may require longer compression times, heat temperatures, and volumes of resin to apply to the printed model. In some embodiments, the resin material is transparent or translucent so that the composite layer 240 is visible through the coating. In other embodiments, the resin is opaque, and thus the composite layer 240 is hidden beneath the coating.

[0096] During the compression molding process, the printed mode composite layer 240 can change its properties and aspects in response to compression, heat, and / or coating. For example, the substrate material 244 can have a lower melting point or heat deflection temperature than the fiber material 248. Thus, the substrate material 244 of the printed model can be melted and molded according to the negative mold 374 of the first block 378, thereby molding or forming the plate 200 during the compression molding process. In one example, the compression molding process can cause the printed model to compress such that one or more of the composite layers 240 reduce in thickness TL, thereby reducing the total thickness TT. The substrate material 244 can also be heat fused by the compression molding process, and it is envisioned that the composite layers 240 are heat fused to each other during the compression molding process. Thus, the compression molding process can transform the composite layers 240 of the plate 200 from separate layers engaged with each other to a monolithic matrix of the substrate material 244 impregnated with multiple continuous strands of the fiber material 248. The heat fusion during compression molding increases the rigidity of the plate 200, and the rigidity of the bending resistance BR, torsional resistance TR, and the like is also increased.

[0097] Additionally, the fiber material 248 may be entangled or rearranged by the compression molding process, resulting in changes in the stiffness, flexibility, and directional strength properties of the printed model. It is contemplated that the compression molding process may melt or deform the fiber material 248 due to exposure to heat and pressure. It is also contemplated that the fiber material 248 may be heat fused to the substrate material 244 and / or the periphery of the fiber material 248 via the compression molding process. Thus, the compression molding process may transform the composite layer 240 of continuous strands of fiber material 248 from separate layers that are disconnected or spaced apart from one another to a monolithic web of fiber material 248 impregnated within the matrix of the substrate material 244. The heat fusion during compression molding increases the stiffness of the plate 200, such as bending resistance BR and torsional resistance TR. Additionally, if a coating is applied to the printed model during the compression molding process, the coating may impart certain properties to the printed model, such as surface roughness, moisture resistance, or vibration isolation, among other features.

[0098] Thus, the plate 200 can be formed in various shapes and sizes and can be provided as part of the footwear 100, such as the sole 104 or the upper 102. In some embodiments, the plate 200 is provided as part of the upper 102, e.g., as part of the insole 126. The plate 200 can be configured to be at least partially customized to affect or enhance gait, posture, stance, propulsion, and mobility, among other needs. For example, the plate 200 may be configured to reduce pain and / or improve performance for users with medical issues or deformities. The fiber reinforcements can increase stiffness in localized regions of the plate 200, such as the rear segment 212, the front segment 220, or the arch segment 216, or some combination thereof. Additionally, stiffness can be increased by arrays and orientations of fibers made of a generally stiff material, or by, for example, printing the fiber material in smaller, denser arrays, or by adding additional composite layers, particularly areas, or by depositing fibers around the perimeter 232. Thus, the bending resistance BR and torsional resistance TR (which account for and are related to the moment of inertia MOI and modulus of elasticity values) can be increased and customized for a particular application. The fiber reinforcement can also provide directional stiffness in localized regions of the plate 200, as well as quasi-isotropic QI properties, by implementing additive manufacturing methods using CFF techniques.

[0099] Example 1

[0100] 10-17, an embodiment of plate 400 is shown in several unfinished states with individual composite layers 404 visible from a top plan view. Specifically, plate 400 is shown at successive stages of an exemplary trial of an additive manufacturing process, i.e., a printing process, as performed in a layer-by-layer configuration using an exemplary CFF technique, samples of which include a first composite layer 404a (see FIG. 10), a second composite layer 404b (see FIG. 11), a third composite layer 404c (see FIG. 12), a fourth composite layer 404d (see FIG. 13), a fifth composite layer 404e (see FIG. 14), a sixth composite layer 404f (see FIG. 15), a seventh composite layer 404g (see FIG. 16), and an eighth composite layer 404h (see FIG. 17). As can be seen from Figures 10-17, the plate 400 defines a centerline axis 228 that bisects the toe end 140 and the heel end 146. The centerline axis 228 is disposed at a centerline angle 408 relative to the reference axis 224. In the illustrated embodiment, the centerline angle 408 is approximately -4 degrees, although other configurations are possible. Additionally, various aspects were measured during an exemplary test printing process and recorded in Table 1 below. Thus, the first layer corresponds to the first composite layer 404a, etc., of Figure 10.

[0101] [Table 1]

[0102] It will be appreciated that plate 400 may include several more composite layers in addition to the eight composite layers 404a-h, and plate 400 may undergo a compression molding process in which a coating is applied. It will be appreciated that the term "array" as used herein may include various types of patterns and arrangements, such as, for example, bostrophedon arrays, tessellation arrays of various polygons, concentric circular or elliptical patterns, motifs of curvilinear geometric shapes, or any other 2D or 3D pattern formed by continuous strands.

[0103] 10, the first composite layer 404a is a base layer comprised of strands of substrate material 244 printed on a substrate array 412a oriented at a base angle 416a relative to the reference axis 224. The base angle 416a may be approximately 45 degrees, although other configurations are possible. In the illustrated embodiment, the base layer 404a is comprised entirely of substrate material 244, which may function as a shell or protective layer to contain the fibrous material 248 that will be deposited in subsequent layers (see FIGS. 11-17). However, in some embodiments, the base layer 404a may be removed prior to installation or assembly within the footwear 100.

[0104] 11, the plate 400 includes a second composite layer 404b including continuous strands of fibrous material 248 printed in a first fiber array 412b oriented parallel to the reference axis 224. The first fiber array 412b is thus oriented at a first fiber angle 416b (not shown) that is different from the base angle 416a. Additionally, the first fiber array 412b of the second composite layer 404b includes turns 420 in the form of U-shaped hairpin bends disposed along portions of the periphery 232 of the plate 400. Additionally, the second composite layer 404b includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the first fiber array near the periphery 232. The peripheral elements 236 are formed from the fibrous material 248 and are provided for additional reinforcement, although the peripheral elements 236 may be formed from other materials and / or provided in more or fewer locations. In other embodiments, the peripheral element 236 may be located further inward from the periphery 232, or the peripheral element 236 may not be provided. With reference to Table 1, the second composite layer 404b has a layer thickness TL of 0.1 mm and a thickness of 1.57 cm. 3 of layer volume VL, of which fibrous material 248 constitutes 96.8%.

[0105] 12, the plate 400 includes a third composite layer 404c including continuous strands of fibrous material 248 printed in a second fiber array 412c oriented at a second fiber angle 416c relative to the reference axis 224. In the illustrated embodiment, the second fiber angle 416c is about -45 degrees. Thus, the second fiber angle 416c is different from the first fiber angle 416b (not shown). Additionally, the second fiber array 412c of the third composite layer 404c includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the third composite layer 404c includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the second fiber array 412c near the periphery 232. With reference to Table 1, the third composite layer 404c has a layer thickness TL of 0.1 mm and a width of 1.56 cm. 3 of layer volume VL, of which fibrous material 248 constitutes 96.8%.

[0106] 13, the plate 400 includes a fourth composite layer 404d including continuous strands of fibrous material 248 printed in a third fiber array 412d oriented at a third fiber angle 416d relative to the reference axis 224. In the illustrated embodiment, the third fiber angle 416d is about 90 degrees. Thus, the third fiber angle 416d is different from the second fiber angle 416c. Additionally, the third fiber array 412d of the fourth composite layer 404d includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the fourth composite layer 404d includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the third fiber array 412d near the periphery 232. With reference to Table 1, the fourth composite layer 404d has a layer thickness TL of 0.1 mm and a thickness of 1.53 cm. 3 of layer volume VL, of which fibrous material 248 constitutes 98.0%.

[0107] 14, the plate 400 includes a fifth composite layer 404e including continuous strands of fiber material 248 printed in a fourth fiber array 412e oriented at a fourth fiber angle 416e relative to the reference axis 224. In the illustrated embodiment, the fourth fiber angle 416e is about 45 degrees. Thus, the fourth fiber angle 416e is different from the third fiber angle 416d. Additionally, the fourth fiber array 412e of the fifth composite layer 404e includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the fifth composite layer 404e includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the fourth fiber array 412e near the periphery 232. The fifth composite layer 404e has a layer thickness TL of 0.1 mm and a layer volume VL of 1.56 cm, as shown in Table 1. 3 Of which, textile materials account for 96.8%.

[0108] 15, the plate 400 includes a sixth composite layer 404f including continuous strands of fiber material 248 printed in a fifth fiber array 412f oriented at a fifth fiber angle 416f relative to the reference axis 224. In the illustrated embodiment, the fifth fiber angle 416f is about -45 degrees. Thus, the fifth fiber angle 416f is different from the fourth fiber angle 416e. Additionally, the fifth fiber array 412f of the sixth composite layer 404f includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the sixth composite layer 404f includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the fifth fiber array 412f near the periphery 232. With reference to Table 1, a layer thickness TL of 0.1 mm and a thickness of 1.54 cm 3 Measurements are provided for a sixth composite layer 404f, which comprises a layer volume VL of 96.8%, of which the fibrous material 248 constitutes 96.8%.

[0109] 16, the plate 400 includes a seventh composite layer 404g including continuous strands of fibrous material 248 printed with a sixth fiber array 412g oriented at a sixth fiber angle 416g relative to the reference axis 224. In the illustrated embodiment, the sixth fiber angle 416g is about 90 degrees. Thus, the sixth fiber angle 416g is different from the fifth fiber angle 416f. Additionally, the sixth fiber array 412g of the seventh composite layer 404g includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the seventh composite layer 404g includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the sixth fiber array 412g near the periphery 232. The seventh composite layer 404g has a layer thickness TL of 0.1 mm and a thickness of 1.54 cm. 3 and a layer volume VL of 98.0% of which is made up of fiber material 248.

[0110] 17, the plate 400 includes an eighth composite layer 404h including continuous strands of fibrous material 248 printed with a seventh fiber array 412h oriented at a seventh fiber angle 416h relative to the reference axis 224. In the illustrated embodiment, the seventh fiber angle 416h is about 90 degrees. Thus, the seventh fiber angle 416h is different from the sixth fiber angle 416g. Additionally, the seventh fiber array 412h of the eighth composite layer 404h includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the eighth composite layer 404h includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the seventh fiber array 412h near the periphery 232. The eighth composite layer 404h has a layer thickness TL of 0.1 mm and a thickness TL of 1.56 cm. 3 and a layer volume VL of 96.8% of which is fiber material 248.

[0111] Thus, one exemplary CFF technique includes the deposition of multiple layers of continuous strands of fiber material 248, stacked or arranged vertically in a continuous composite layer 404, arranged in different arrays 412, and arranged at various angles 416 relative to the reference axis 224. Furthermore, each fiber array 412 includes continuous strands of fiber material 248 that extend continuously in-plane between the toe end 140 and the heel end 146 of the plate 400. That is, the CFF technique used to manufacture the plate 400 includes several composite layers 404 in which the fiber material 248 is deposited in fiber arrays 412 that are uniform and continuous throughout the posterior segment 212, the arch segment 216, and the anterior segment 220, and the fiber arrays 412 are also uniform between the medial surface 118 and the lateral surface 116 of the plate 400. Furthermore, each fiber array 412 is comprised of continuous strands of fiber material 412 that are distinct and separated from the fiber arrays 412 of adjacent composite layers 404. To that end, a cutter (not shown) in the printer 300 is used to define the continuous strands of each fiber array 412 .

[0112] In addition, the fiber angle 416 is different from the fiber angle 416 of the adjacent composite layer 404. Moreover, the fiber array 412 of each composite layer 404 defines a fiber surface area FSAL of the composite layer 404, which can then be quantified as a percentage of the total surface area SAL defined by the composite layer 404. In one example, the fiber array 412 comprises at least about 90% of the layer surface area. Since the composite layer 404 extends throughout the entire plate 400 and partially defines the plate 400 and its periphery 232, the layer surface area SAL is generally equal to the in-plane surface area (SAP) of the plate 400. Thus, the fiber surface area of ​​the fiber array 412 corresponds to the in-plane surface area of ​​the plate 400. To that end, the fiber array 412 is continuously printed over substantially the entire in-plane surface area SAP of the plate 400, i.e., the fiber array 412 comprises at least about 90% of the in-plane surface area SAP of the plate 400. It will be understood that the fiber fraction FPL of the layer volume VL corresponds proportionally to the fiber surface area FSAL covered by the fiber array 412. However, in some embodiments, the fiber fraction FPL may not correspond to the fiber surface area FSAL due to the introduction of third elements and / or materials, or due to the concentration of the fiber material 248 in a particular area or section of the composite layer 404 and / or plate 400. In some embodiments, the fiber surface area FSAL of each fiber array 412 is different from the fiber surface area FSAL of the fiber array 412 of an adjacent composite layer 404.

[0113] With reference to FIG. 18, another embodiment of a plate 500 is provided for use in a sole structure 504 for footwear 100. The plate 500 and sole structure 504 of FIG. 18 are similar to the plates 200, 400 and sole structure 104, and therefore like reference numerals are used to indicate like elements. In FIG. 18, the plate 500 includes a medial fork 508 and a lateral fork 512 separated by a gap 516 in the front segment 220. The plate 500 narrows, or is measured in the X direction, relative to a reference plane 224 moving longitudinally toward the heel end 146. That is, the plate 500 narrows from the front segment 220 to the arch segment 216 and also narrows from the arch segment 216 to the rear segment 212. In the illustrated embodiment, the sole 504 further includes an outsole 520 and a midsole 528 to which the plate 500 is attached.

[0114] Plate 500, like plates 200 and 400, is manufactured by additive manufacturing, and plate 500 includes multiple composite layers (not shown) including various orientations of fiber material 248 and substrate material 244. Thus, plate 500 is sized and shaped to have a customized bending resistance BR and torsional resistance TR. For example, due to the location of gap 516 between inner fork 508 and outer fork 512, front segment 220 of plate 500 has a smaller material volume VL and VT than those of plates 200, 400. This reduces bending resistance BR and torsional resistance TR compared to plates 200, 400. In addition, rear segment 212 also defines a reduced VL and VT than VL and VT of plates 200, 400. However, arch segment 216 of plate 500 defines a VT and VL that are equal to or greater than the VT and VL of plates 200, 400. Thus, the plate 500 is tailored to provide a particular bending resistance BR and torsional resistance TR compared to the plates 200, 400 by modifying the shape and size of the plate 500.

[0115] Additionally, the medial fork 508 and the lateral fork 512 of the plate 500 may be configured to have different characteristics from one another. For example, the medial fork 508 may have a greater stiffness, e.g., bending resistance BR, than the lateral fork 512 to provide the user with increased propulsion on or near the medial side of the ball of the foot, i.e., near the distal toe. In contrast, the lateral fork 512 may have a greater flexibility, e.g., a lower bending resistance BR, than the medial fork 508 to provide the user with increased comfort on or near the lateral side of the ball of the foot, e.g., near the distal toe.

[0116] 1-3 and 18, the plate 500 is provided as part of a sole structure 504 configured to be assembled with the upper 102. In particular, the plate 500 is configured to be disposed between the outsole 520 and the upper 102, such that the plate 500 contacts both the outsole 520 and the upper 102. To that end, the plate 500 extends through the midsole 528, and specifically, the rear segment 212 of the plate 500 extends through a slot 532 formed through the midsole 528. In the illustrated embodiment, the plate 500 gradually curves along the front segment 220 and the arch segment 216 with respect to the horizontal plane H, and the plate 500 has an increased curvature with respect to the horizontal plane H along the arch segment 216 and the rear segment 212 as compared to the curvature of the front segment 220.

[0117] When assembled, the rear segment 212 of the plate 500 rests on the platform 536 so as to be flush with the bed 540 of the midsole 528. When the upper 102 is attached to the midsole 528, the insole 126 of the upper 102 is positioned along the bed 540 and rear segment 212 of the plate 500. Thus, when the sole 504 is assembled, the plate 500 extends in the X and Y directions and is positioned at a downward angle relative to a horizontal plane H that is coplanar with at least a portion of the bed 540 of the midsole 528 and / or the insole 126 of the upper 102. The downward angle is at least about 5 degrees, but may be 10 degrees or more. At such a downward angle, in combination with a particular curvature, the plate 500 is configured to deflect under an applied load during use, thereby allowing the plate 500 to bounce and thus provide propulsion to the user's gait during light loads, e.g., simple walking stride. In combination with the particular shape and size of the plate 500, as described above, the plate 500 is positioned within the sole 504 to increase responsiveness, thereby making propulsion easier, i.e., with a lighter load, as compared to a plate laid flat along the midsole 528.

[0118] Thus, the plate 200, 400, 500 can be formed in various shapes and sizes and can be provided as part of the footwear 100, such as the sole 104 or the upper 102. In some embodiments, the plate 400 is provided as part of the upper 102, such as part of the insole 126. The plate 200, 400, 500 can be configured to be at least partially customized to affect or improve gait, posture, stance, propulsion, and agility, among other needs. For example, the plate 200, 400, 500 may be configured to reduce pain and / or improve performance for users with medical issues or deformities. The fiber reinforcement can increase the stiffness of localized regions of the plate 200, 400, such as in the posterior segment 212, the anterior segment 220, or the arch segment 216, or some combination thereof. In addition, stiffness can be increased by arrays and orientations of fibers made of generally stiff materials, or, for example, by printing the fiber material in smaller and denser arrays, or by adding additional composite layers, particularly in areas, or by depositing fibers around the periphery 232. Thus, the moment of inertia MOI and the elastic modulus values, and the associated bending resistance BR and torsional resistance TR, can be increased and customized for specific applications. Fiber reinforcements can also provide directional stiffness in localized areas of the plate 200, 400, 500, as well as quasi-isotropic QI properties, by implementing additive manufacturing methods using CFF techniques.

[0119] FIG. 19 illustrates another embodiment of a plate 600 manufactured by the additive manufacturing process described above. The plate 600 is configured as a single sole structure 104, the plate 600 including the entire sole structure 104 to which the upper 102 (see FIGS. 1-3) is attached. In particular, the plate 600 includes a plurality of traction elements 604 that are monolithically provided as part of the plate 600. Thus, the same additive manufacturing process, and in some examples, the same material, can be used to manufacture the plate 600 and the traction elements 604. The traction elements 604 are thus composite elements including the substrate material 244 and the fiber material 248, as described above in connection with FIGS. 1-18. Referring to FIG. 20, which is a cross-sectional view of one of the traction elements 604 of FIG. 19, the fiber material 248 is wound in a concentric path within the traction element 604. Additionally, the towing element 604 defines an outer diameter D that narrows as the towing element 604 extends away from the plate 600. Thus, the concentric paths of the fibrous material 248 tighten or expand within the towing element 604 in proportion to the diameter D. In this manner, the towing element 604 is reinforced to have similar strength-to-weight characteristics as the plates 200, 400, 500 described above.

[0120] 21, a schematic diagram of one example of an opening 620 that may be provided in a plate 600 is shown. In the illustrated embodiment, the fibrous material 248 extends in a concentric path around the opening 620 in proportion to the diameter D1 defined by the opening 620. In this manner, the fibrous material 248 is used to reinforce the opening 620 of the plate 600. Such openings 620 may be formed in the plate 600 as through holes or as voids or cavities that are not exposed to the exterior of the plate 600.

[0121] It is envisioned that any of the plates described in this disclosure include embedded functionality in addition to the structural rigidity properties discussed above. For example, it is envisioned that the fabric material 248 has or is modified to have an electrically conductive material, a thermally conductive material, an electrically insulating material, a thermally insulating material, an optically transparent material, or a fluid-permeable material. Additionally or alternatively, a device (not shown) may be embedded within any of the plates of this disclosure. In one example, the device (not shown) may be a sensor, such as a transducer, an accelerometer, a geolocation sensor, a temperature sensor, a humidity sensor, or a moisture sensor. Additionally, the device (not shown) may be capable of providing a haptic feedback to the user, so that the user can be notified to avoid prolonged standing or sitting or immobility. Additionally, the device (not shown) may be an object or structural element, such as, for example, an air-filled or fluid-filled bladder or pod. It is further envisioned that the device (not shown) may be capable of harvesting and storing energy caused by deformation of the plate and / or footwear during use, such as, for example, a piezoelectric transducer.

[0122] In other embodiments, other configurations are possible. For example, certain features and combinations of features presented with respect to certain embodiments in the above discussion can be utilized in other embodiments and other combinations, as appropriate. Furthermore, any of the embodiments described herein can be modified to include any of the structures or methods disclosed in connection with other embodiments. Additionally, the disclosure is not limited to the type of footwear product specifically shown. Furthermore, the footwear product aspects of any of the embodiments disclosed herein may be modified to work with any type of footwear, apparel, or other athletic equipment.

[0123] As previously mentioned, although the present invention has been described above with reference to specific embodiments and examples, it will be understood by those skilled in the art that the present invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications, and departures from the embodiments are intended to be encompassed by the claims appended hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference herein as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the present invention are set forth in the following claims. [Industrial Applicability]

[0124] Numerous variations on the present invention will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this specification is to be construed as illustrative only and is presented for the purpose of enabling any person skilled in the art to make and use the invention. The exclusive rights to all modifications that come within the scope of the appended claims are reserved.

Claims

1. 1. A method of manufacturing a component for a sole structure of an article of footwear, the method comprising: A three dimensional printer having a platform, a first head for receiving a first supply, and a second head for receiving a second supply, printing a base layer on the platform, the base layer comprising a substrate material and defining a longitudinal axis; printing a first fibrous layer continuously onto the base layer, the first fibrous layer defining a first fiber orientation disposed at a first angle relative to the longitudinal axis; printing a second fibrous layer consecutively onto the first fibrous layer, the second fibrous layer defining a second fiber orientation disposed at a second angle relative to the longitudinal axis, the first angle being different from the second angle; The printed model is subjected to a compression molding process, and the printed model includes at least the base layer, the first fiber layer, and the second fiber layer.

2. the first fibrous layer comprises at least 60% substrate material; The method of claim 1.

3. the second fibrous layer comprises at least 50% fibrous material; The method of claim 1.

4. the first fibrous layer and the second fibrous layer define different layer volumes. The method of claim 1.

5. The first fiber layer includes at least one of carbon fiber, aramid fiber, boron fiber, or glass fiber. The method of claim 1.

6. The printed model comprises at least five fiber layers. The method of claim 1.

7. The printed model includes an arch segment extending between a rear segment and a front segment. The method of claim 1.

8. A transparent resin is applied to the printed model in the compression mold. The method of claim 1.

9. the printed model includes a third fiber layer defining a third fiber orientation disposed at a third angle relative to the longitudinal axis, the third angle being equal to the first angle, the third fiber layer being separated from the first fiber layer by the second fiber layer; The method of claim 1.

10. A plate for a sole structure of an article of footwear, comprising: The footwear includes an upper having an insole; The plate is An inner surface opposite the outer surface; A heel end opposite the toe end, a base layer comprising a substrate material; a plurality of composite layers coupled to the base layer, each composite layer including a first volume of substrate material and a second volume of fibrous material; the first volume of substrate material and the second volume of fibrous material are different; each of the composite plies defines a first fiber orientation, the first fiber orientation varying between adjacent composite plies; The plate is printed layer by layer to define top and bottom surfaces, at least a portion of the top surface being spaced apart from the insole of the upper.

11. the composite ply is disposed as a stack between the top and bottom surfaces of the plate, the stack having quasi-isotropic properties; 11. The plate of claim 10.

12. Each of the composite layers has anisotropy, and the anisotropy differs between adjacent composite layers.

12. The plate of claim 11.

13. The anisotropy includes at least one of bending resistance, torsional resistance, or tensile stiffness; 13. The plate of claim 12.

14. the first volume of substrate material is less than the second volume of fibrous material; 11. The plate of claim 10.

15. the second volume of fibrous material comprises at least one of carbon fiber, aramid fiber, boron fiber, or glass fiber; 11. The plate of claim 10.

16. 1. A method of using a three-dimensional printer and a compression mold to manufacture a plate for a footwear product, the method comprising: providing a supply of substrate material to be fed to a first head of the printer; providing a supply of fibrous material to be fed to a second head of the printer; providing a preformed model on a platform within said printer; providing a design model to the printer, the first head and the second head being selectively activated and deactivated to print at least two composite layers onto the preformed model; The at least two composite layers are separated from the preformed model and received within the compression mold.

17. each of the at least two composite layers includes a continuous fiber strand provided by the second head; 17. The method of claim 16.

18. The plate includes an anterior segment having a first stiffness, an arch segment having a second stiffness, and a posterior segment having a third stiffness.

17. The method of claim 16.

19. the first stiffness is greater than the second stiffness, and the third stiffness is greater than the first stiffness; 20. The method of claim 18.

20. the first stiffness, the second stiffness, and the third stiffness are equal; 20. The method of claim 18.

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