Foam-covered boards for footwear
The sole structure with a curved footwear plate and cushioning elements addresses the inefficiency caused by flat rigid plates, enhancing energy return and reducing ankle strain, thus improving running performance.
Patent Information
- Application Number
- JP2020180295
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2016-08-26
- Filing Date
- 2020-10-28
- Publication Date
- 2025-09-01
- Estimated Expiration
- 2036-08-26
AI Technical Summary
Conventional footwear sole structures with embedded flat rigid plates increase mechanical demands on the ankle during running by stiffening the sole structure, leading to reduced efficiency, especially over longer distances, due to increased energy loss at the metatarsophalangeal (MTP) joint.
A sole structure design featuring a footwear plate with a curved portion facing the MTP joint, reducing the lever arm length and push-off moment at the ankle by incorporating a curved portion with a constant radius of curvature, and optionally including fluid-filled chambers and multiple cushioning layers for enhanced cushioning and energy return.
The design reduces mechanical demands on the ankle, enhances energy return, and improves running efficiency by minimizing energy loss at the MTP joint, thereby optimizing performance over longer distances.
Smart Images

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Abstract
Description
[Technical Field]
[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Patent Application No. 15 / 248,059, filed August 26, 2016, U.S. Provisional Patent Application No. 62 / 236,649, filed October 2, 2015, and U.S. Provisional Patent Application No. 62 / 308,626, filed March 15, 2016, which are incorporated by reference in their entireties.
[0002] The present disclosure relates to an article of footwear that includes a sole structure with a footboard and foam for improving efficiency in the performance of the footwear during a running movement. [Background technology]
[0003] This section provides background information related to the present disclosure that is not necessarily prior art.
[0004] Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material to receive, secure, and support a foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper adjacent the bottom surface of the foot is attached to the sole structure.
[0005] The sole structure generally includes a laminated construction extending between the ground surface and the upper. One layer of the sole structure includes an outsole, which provides abrasion resistance and traction with the ground surface. The outsole may be formed from rubber or other materials that enhance traction with the ground surface in addition to providing durability and abrasion resistance. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning to the foot and is generally formed at least in part from a polymer foam material that resiliently compresses under an applied load to cushion the foot by attenuating ground reaction forces. The midsole may define a bottom surface on one side opposite the outsole and a midsole on the opposite side, which may be contoured to match the contours of the bottom surface of the foot. The sole structure may also include a comfort insole or footliner located within a void adjacent the bottom portion of the upper.
[0006] The metatarsophalangeal (MTP) joint of the foot is known to absorb energy as it bends through dorsiflexion during running. Because the MTP joint does not move through plantarflexion until the foot pushes off the ground, it is known that the MTP joint does not return most of the energy it absorbs to the running motion and therefore becomes a source of energy drain during running. Embedded flat rigid plates with longitudinal stiffness within the sole structure are known to increase the overall stiffness of the sole structure. While the use of flat plates stiffens the sole structure toward reducing energy loss at the MTP joint by preventing the MTP joint from absorbing energy through dorsiflexion, the use of flat plates adversely increases the mechanical demands on the plantarflexors of the ankle of the foot, thereby reducing the efficiency of the foot during running, especially over longer distances. Summary of the Invention [Means for solving the problem]
[0007] The drawings described herein are for illustrative purposes of selected configurations only and are not intended to limit the scope of the present disclosure. [Brief explanation of the drawings]
[0008] [Figure 1] FIG. 1 is a top perspective view of an article of footwear in accordance with the principles of the present disclosure. [Figure 2] 2 is an exploded view of the article of footwear of FIG. 1 showing the footwear plate positioned on the cushioning member within the void between the inner surface of the outsole and the bottom surface of the midsole. [Figure 3] 3 is a cross-sectional view taken along line 3-3 of FIG. 1 showing a footwear plate positioned on a cushioning member within a void between an inner surface of an outsole and a bottom surface of a midsole. [Figure 4] FIG. 1 is a top perspective view of an article of footwear in accordance with the principles of the present disclosure. [Figure 5] 5 is an exploded view of the article of footwear of FIG. 4 showing the footwear plate positioned between the first and second cushioning members within the void between the inner surface of the outsole and the bottom surface of the midsole. [Figure 6] 6 is a cross-sectional view taken along line 6-6 of FIG. 4 showing a footwear plate disposed between a first cushioning member and a second cushioning member within a void space between an inner surface of an outsole and a bottom surface of a midsole. [Figure 7] FIG. 1 is a top perspective view of an article of footwear in accordance with the principles of the present disclosure. [Figure 8] 8 is an exploded view of the article of footwear of FIG. 7 showing a cushioning member received within a void between an inner surface of the outsole and a bottom surface of the midsole, and a footwear plate disposed on the inner surface in a forefoot region of the footwear and embedded within the cushioning member in a heel region of the footwear. [Figure 9] 9 is a cross-sectional view taken along line 9-9 of FIG. 7 showing the cushioning member received within a void between the inner surface of the outsole and the bottom surface of the midsole, and the footwear plate positioned on the inner surface in the forefoot region of the footwear and embedded within the cushioning member in the heel region of the footwear. [Figure 10] FIG. 1 is a top perspective view of an article of footwear in accordance with the principles of the present disclosure. [Figure 11]11 is an exploded view of the article of footwear of FIG. 10 showing a cushioning member received within a void between the inner surface of the outsole and the bottom surface of the midsole, and a foot plate embedded within the cushioning member in the forefoot region of the footwear and positioned between the cushioning member and the bottom surface of the midsole in the heel region of the footwear. [Figure 12] 12 is a cross-sectional view taken along line 12-12 of FIG. 10 showing a cushioning member received within a void between the inner surface of the outsole and the bottom surface of the midsole, and a shoe plate embedded within the cushioning member in the forefoot region of the footwear and positioned between the cushioning member and the bottom surface of the midsole in the heel region of the footwear. [Figure 13] FIG. 1 is a top perspective view of an article of footwear in accordance with the principles of the present disclosure. [Figure 14] 14 is an exploded view of the article of footwear of FIG. 13 showing a cushioning member received within a void between an inner surface of the outsole and a bottom surface of the midsole, and a footwear plate embedded within the cushioning member in a forefoot region of the footwear and positioned between the cushioning member and the inner surface of the outsole in a heel region of the footwear. [Figure 15] 15 is a cross-sectional view taken along line 15-15 of FIG. 13 showing a cushioning member received within a void between an inner surface of an outsole and a bottom surface of a midsole, and a footwear plate embedded within the cushioning member in a forefoot region of the footwear and positioned between the cushioning member and the inner surface of the outsole in a heel region of the footwear. [Figure 16] FIG. 1 is a top perspective view of a footwear plate for use in an article of footwear according to the principles of the present disclosure; [Figure 17] FIG. 17 is a side view of the footwear plate of FIG. 16. [Figure 18] FIG. 17 is a top view of the footwear plate of FIG. 16. [Figure 19] FIG. 1 is a top perspective view of a footwear plate for use in an article of footwear according to the principles of the present disclosure; [Figure 20] FIG. 20 is a side view of the footwear plate of FIG. 19. [Figure 21] FIG. 20 is a top view of the footwear plate of FIG. 19. [Figure 22] FIG. 1 is a top perspective view of a footwear plate for use in an article of footwear according to the principles of the present disclosure; [Figure 23] FIG. 23 is a side view of the footwear plate of FIG. 22. [Figure 24] FIG. 23 is a top view of the footwear plate of FIG. 22. [Figure 25] FIG. 1 is a top view of a footwear plate for use in an article of footwear according to the principles of the present disclosure. [Figure 26] FIG. 1 is a top view of a footwear plate for use in the forefoot region of an article of footwear in accordance with the principles of the present disclosure. [Figure 27] FIG. 1 is a top view of a footwear plate for use in an article of footwear according to the principles of the present disclosure. [Figure 28] FIG. 1 is a top view of a footwear plate for use in an article of footwear according to the principles of the present disclosure. [Figure 29] FIG. 1 is a top view of a footwear plate for use in an article of footwear according to the principles of the present disclosure. [Figure 30] FIG. 1 is a top view of a footwear plate for use in an article of footwear according to the principles of the present disclosure. [Figure 31] FIG. 1 is a top perspective view of an article of footwear in accordance with the principles of the present disclosure. [Figure 32] 32 is a cross-sectional view taken along line 32-32 of FIG. 31 showing a footwear plate positioned between the outsole and midsole in the forefoot region of the footwear and between the cushioning member and midsole in the heel region of the footwear. [Figure 33] FIG. 1 is a top perspective view of an article of footwear in accordance with the principles of the present disclosure. [Figure 34] 34 is a cross-sectional view taken along line 34-34 of FIG. 33 showing the footwear plate disposed between the outsole and the cushioning member. [Figure 35] FIG. 1 is a top perspective view of an article of footwear in accordance with the principles of the present disclosure. [Figure 36] 36 is a cross-sectional view taken along line 36-36 of FIG. 35 showing a plurality of openings formed through the outsole and the cushioning member to expose a footwear plate disposed between the cushioning member and the midsole. [Figure 37] FIG. 1 is a top perspective view of an article of footwear in accordance with the principles of the present disclosure. [Figure 38] FIG. 38 is an exploded view of the article of footwear of FIG. 37 showing a fluid-filled bladder positioned on the cushioning member within the void space between the inner surface of the outsole and the bottom surface of the midsole. [Figure 39] 39 is a cross-sectional view taken along line 39-39 of FIG. 37 showing a fluid-filled bladder disposed in the cushioning member within the void space between the inner surface of the outsole and the bottom surface of the midsole. [Figure 40A] 1A-1C illustrate various prepreg fiber sheets used in forming a footwear board according to the principles of the present disclosure. [Figure 40B] 1A-1C illustrate various prepreg fiber sheets used in forming a footwear board according to the principles of the present disclosure. [Figure 40C] 1A-1C illustrate various prepreg fiber sheets used in forming a footwear board according to the principles of the present disclosure. [Figure 40D] 1A-1C illustrate various prepreg fiber sheets used in forming a footwear board according to the principles of the present disclosure. [Figure 40E] 1A-1C illustrate various prepreg fiber sheets used in forming a footwear board according to the principles of the present disclosure. [Figure 41] FIG. 1 is an exploded view of a stack of prepreg fiber sheets used to form a footwear plate in accordance with the principles of the present disclosure. [Figure 42A] 1 illustrates various layers of fiber strands used in forming a footwear plate according to the principles of the present disclosure. [Figure 42B] 1 illustrates various layers of fiber strands used in forming a footwear plate according to the principles of the present disclosure. [Figure 42C] 1 illustrates various layers of fiber strands used in forming a footwear plate according to the principles of the present disclosure. [Figure 42D] 1 illustrates various layers of fiber strands used in forming a footwear plate according to the principles of the present disclosure. [Figure 42E] 1 illustrates various layers of fiber strands used in forming a footwear plate according to the principles of the present disclosure. [Figure 43]FIG. 1 is an exploded view of layers of fiber strands used to form a footwear plate in accordance with the principles of the present disclosure. [Figure 44] 1 is a perspective view of a mold for use in forming a footwear plate according to the principles of the present disclosure, shown in combination with a stack of fibers prior to being formed into the footwear plate; FIG. [Figure 45] 1 is a perspective view of a mold for use in forming a footwear plate according to the principles of the present disclosure, shown in combination with the formed footwear plate; FIG. DETAILED DESCRIPTION OF THE INVENTION
[0009] Corresponding reference numbers indicate corresponding parts throughout the drawings.
[0010] Example configurations are now more fully described with reference to the accompanying drawings. The example configurations are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of the disclosed configurations. It will be apparent to those skilled in the art that specific details need not be used, that the example configurations can be embodied in many different forms, and that the specific details and example configurations should not be construed to limit the scope of the disclosure.
[0011] The terminology used herein is for the purpose of describing specific example configurations only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" may be intended to include the plural unless the context clearly dictates otherwise. The terms "comprise," "include," and "have" are inclusive and thus specify the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The steps, processes, and acts of methods described herein should not be construed as necessarily requiring their performance in the specific order described or illustrated, unless expressly identified as an order of performance. Additional or alternative steps may be employed.
[0012] When an element or layer is referred to as being "on," "engaged," "coupled," "attached," or "bonded" to another element or layer, the element or layer may be directly on, directly engaged with, directly coupled to, directly attached to, or directly bonded to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged," "directly coupled," "directly attached," or "directly bonded" to another element or layer, there may be no intervening elements or layers. Other words used to describe relationships between elements should be interpreted similarly (e.g., "between" and "directly between," "adjacent" and "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.
[0013] Terms such as "first," "second," and "third" may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as "first," "second," and other numerical terms do not imply sequentiality or order unless clearly dictated by context. Thus, a first element, first component, first region, first layer, or first section detailed below may be termed a second element, second component, second region, second layer, or second section without departing from the teachings of the example configurations.
[0014] One aspect of the disclosure provides a sole structure for an article of footwear having an upper portion. The sole structure includes an outsole, a plate disposed between the outsole and the upper, and a first cushioning layer disposed between the recessed portion and the upper. The plate includes a forward-most portion disposed in a forefoot region of the sole structure and a rearward-most point disposed closer to the heel region of the sole structure than the forward-most point. The plate also includes a recessed portion extending between the forward-most point and the rearward-most point and including a constant radius of curvature from the forward-most point to a metatarsophalangeal (MTP) point of the sole structure. The MTP point faces the metatarsophalangeal (MTP) joint of the foot during use.
[0015] Implementations of the present disclosure may include one or more of the following optional features: In some implementations, the forward-most point and the rearward-most point are coplanar. The plate may include a substantially flat portion disposed in the heel region of the sole structure. The rearward-most point may be located within the substantially flat portion.
[0016] In some examples, the sole structure includes a fused portion disposed between the recessed portion and the substantially flat portion and connecting the recessed portion and the substantially flat portion. The fused portion may include a substantially constant curvature. A forward-most point and a rearward-most point may be coplanar at the junction of the fused portion and the substantially flat portion.
[0017] The sole structure may include a second cushioning layer disposed between the substantially flat portion and the upper. A third cushioning layer may be disposed between the outsole and the plate. In some examples, the third cushioning layer is disposed in the heel region. The third cushioning layer may extend from the heel region to the forefoot region.
[0018] The sole structure may include at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate. The at least one fluid-filled chamber may be disposed within at least one of the second and third cushioning layers.
[0019] In some instances, the MTP point is located approximately thirty percent (30%) of the total length of the plate from the most anterior point. The center of the radius of curvature may be located at the MTP point. The constant radius of curvature may extend from the most anterior point beyond the MTP point. The constant radius of curvature may extend from the most anterior point beyond the MTP point for at least forty percent (40%) of the total length of the plate from the most anterior point.
[0020] In some examples, the outsole includes a ground-contacting surface and an inner surface formed on a side of the outsole opposite the ground-contacting surface. The inner surface may be attached directly to the plate. The inner surface may be attached to the plate adjacent the recessed portion.
[0021] Another aspect of the disclosure provides a sole structure for an article of footwear having an upper. The sole structure includes an outsole, a plate disposed between the outsole and the upper, and a first cushioning layer disposed between a curved portion and the upper. The plate includes a forward-most point disposed in a forefoot region of the sole structure and a rearward-most point disposed closer to the heel region of the sole structure than the forward-most point. The plate also includes a curved portion extending between the forward-most point and the rearward-most point, connecting the forward-most point and the rearward-most point, and including a constant radius of curvature from the forward-most point to a metatarsophalangeal (MTP) point of the sole structure. The MTP point faces the metatarsophalangeal (MTP) joint of the foot during use.
[0022] This aspect may include one or more of the following optional features: In some implementations, the forward-most point and the rearward-most point are coplanar; The plate may include a substantially flat portion disposed in a heel region of the sole structure, the rearward-most point being located within the substantially flat portion.
[0023] In some examples, the sole structure includes a fused portion disposed between the curved portion and the substantially flat portion and connecting the curved portion and the substantially flat portion. The fused portion may include a substantially constant curvature. A forward-most point and a rearward-most point may be coplanar at the junction of the fused portion and the substantially flat portion.
[0024] The sole structure may include a second cushioning layer disposed between the substantially flat portion and the upper. A third cushioning layer may be disposed between the outsole and the plate. The third cushioning layer may be disposed in the heel region. The third cushioning layer may extend from the heel region to the forefoot region.
[0025] In some examples, the sole structure includes at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate. The at least one fluid-filled chamber may be disposed within at least one of the second and third cushioning layers.
[0026] In some instances, the MTP point is located approximately thirty percent (30%) of the total length of the plate from the most anterior point. The center of the radius of curvature may be located at the MTP point. The constant radius of curvature may extend from the most anterior point beyond the MTP point. The constant radius of curvature may extend from the most anterior point beyond the MTP point for at least forty percent (40%) of the total length of the plate from the most anterior point.
[0027] The outsole may include a ground-contacting surface and an inner surface formed on a side of the outsole opposite the ground-contacting surface. The inner surface may be attached directly to the plate. The inner surface may be attached to the plate adjacent the curved portion.
[0028] Yet another aspect of the disclosure provides a sole structure for an article of footwear having an upper. The sole structure includes an outsole, a plate disposed between the outsole and the upper, and a first cushioning layer disposed between a curved portion and the upper. The plate includes a forward-most point disposed in a forefoot region of the sole structure and a rearward-most point disposed closer to the heel region of the sole structure than the forward-most point. The plate also includes a curved portion extending between and connecting the forward-most and rearward-most points, the curved portion including a circular curve from the forward-most point to a metatarsophalangeal (MTP) point of the sole structure. The MTP point faces the metatarsophalangeal (MTP) joint of the foot during use.
[0029] This aspect may include one or more of the following optional features: In some implementations, the forward-most point and the rearward-most point are coplanar. The plate may include a substantially flat portion disposed in the heel region of the sole structure. The rearward-most point may be located within the substantially flat portion. The plate may include a substantially flat portion disposed in the heel region of the sole structure. The rearward-most point may be located within the substantially flat portion.
[0030] In some examples, the sole structure includes a fused portion disposed between the curved portion and the substantially flat portion and connecting the curved portion and the substantially flat portion, the fused portion including a substantially constant curvature, and a forward-most point and a rearward-most point can be coplanar at the junction of the fused portion and the substantially flat portion.
[0031] The sole structure may include a second cushioning layer disposed between the substantially flat portion and the upper. A third cushioning layer may be disposed between the outsole and the plate. The third cushioning layer may be disposed in the heel region. In some examples, the third cushioning layer extends from the heel region to the forefoot region.
[0032] The sole structure may include at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate. The at least one fluid-filled chamber may be disposed within at least one of the second and third cushioning layers.
[0033] In some instances, the MTP point is located approximately thirty percent (30%) of the total length of the plate from the most anterior point. The center of the circular curvature may be located at the MTP point. The circular curvature may extend from the most anterior point beyond the MTP point. The circular curvature may extend from the most anterior point beyond the MTP point for at least forty percent (40%) of the total length of the plate from the most anterior point.
[0034] In some implementations, the outsole includes a ground-contacting surface and an inner surface formed on a side of the outsole opposite the ground-contacting surface. The inner surface may be attached directly to the plate. Additionally or alternatively, the inner surface may be attached to the plate adjacent the curved portion. In some examples, the sole structure further includes a second cushioning layer disposed on a side of the plate opposite the first cushioning layer to form at least a portion of the outsole.
[0035] The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims.
[0036] During running, the footwear application point that provides the push-off force from the ground surface is located in the forefoot of the footwear. The footwear application point faces the metatarsophalangeal (MTP) joint of the foot. The distance between the athlete's ankle joint and the line of action of the application point that provides the push-off force defines a lever arm distance centered on the ankle. The mechanical demand on the ankle plantarflexors (e.g., the calf tendon group) can be based on the push-off moment at the ankle, which is determined by multiplying the lever arm length by the magnitude of the push-off force controlled by the athlete. A rigid, flat footwear plate generally increases the mechanical demand at the ankle and moves the application point with the ground surface forward due to the rigid, flat plate. As a result, the lever arm distance and the push-off moment increase at the ankle joint. Implementations herein are directed to shortening the lever arm length from the ankle joint to reduce the push-off moment at the ankle by providing a rigid footwear plate that includes a curved portion facing the MTP joint.
[0037] 1-3, an article of footwear 10 is provided and includes an upper 100 and a sole structure 200 attached to the upper 100. The article of footwear 10 can be divided into one or more sections. These sections may include a forefoot section 12, a midfoot section 14, and a heel section 16. The forefoot section 12 can correspond to the toes and joints connecting the metatarsals with the phalanges of the foot during use of the footwear 10. The forefoot section 12 can correspond to the MTP joint of the foot. The midfoot section 14 can correspond to the arch area of the foot during use of the article of footwear 10, and the heel section 16 can correspond to the rear portion of the foot, including the calcaneus. Footwear 10 can include a lateral section 18 and a medial section 20 that correspond to either side of the footwear 10 and extend through sections 12, 14, and 16, respectively.
[0038] The upper 100 includes an interior surface defining an interior cavity 102 that receives and secures a foot for support in the sole structure 200 during use of the article of footwear 10. An ankle opening 104 in the heel portion 16 can provide access to the interior cavity 102. For example, the ankle opening 104 can receive a foot for securing the foot within the cavity 102 and can facilitate entry and exit of the foot into and from the interior cavity 102. In some examples, one or more fasteners 106 extend along the upper 100 to adjust the fit of the interior cavity 102 around the foot while facilitating entry and exit of the foot. The upper 100 can include openings, such as eyelets and / or other engagement features, such as woven or mesh hoops, that receive the fasteners 106. The fasteners 106 can comprise laces, straps, cords, hook-and-loop fasteners, or any other suitable type of fastener.
[0039] Upper 100 may include a tongue portion 110 extending between interior void 102 and fastener 106. Upper 100 may be formed from one or more materials that are sewn or adhesively bonded together to form interior void 102. Suitable materials for the upper include, but are not limited to, fabric, foam, leather, and synthetic leather. Materials may be selected and positioned to impart characteristics of durability, breathability, abrasion resistance, flexibility, and comfort.
[0040] In some implementations, sole structure 200 includes outsole 210, cushioning member 250, and midsole 220 arranged in a laminated configuration. Sole structure 200 (e.g., outsole 210, cushioning member 250, and midsole 220) define a longitudinal axis L. For example, outsole 210 engages the ground surface during use of the article of footwear 10, midsole 220 is attached to upper 100, and cushioning member 250 is disposed therebetween to separate midsole 220 from outsole 210. For example, cushioning member 250 defines a bottom surface 252 that faces outsole 210 and a top surface 254 that is disposed on a side of cushioning member 250 opposite bottom surface 252 and faces midsole 220. Top surface 254 may be shaped to conform to the contours of the bottom surface (e.g., plantar) of the foot within interior cavity 102. In some examples, sole structure 200 may incorporate additional layers, such as insole 260 ( FIGS. 2 and 3 ), or a midsole that can be positioned within interior cavity 102 of upper 100 to receive the plantar surface of the foot to enhance the comfort of footwear 10. In some examples, sidewall 230 surrounds at least a portion of the periphery of cushioning member 250 and separates cushioning member 250 from midsole 220 to define cavity 240 therebetween. For example, sidewall 230 and upper surface 254 of cushioning member 250 may cooperate to hold and support the foot on cushioning member 250 when interior cavity 102 receives the foot. For example, sidewall 230 may define a periphery around at least a portion of the periphery of contoured upper surface 254 of cushioning member 250 to encase the foot during use of footwear 10 when performing a walking or running motion. The perimeter may extend around the periphery of the midsole 220 when the cushioning member 250 is attached to the midsole 220 .
[0041] In some configurations, footwear plate 300 is positioned below midsole 220 on upper surface 254 of cushioning member 250 to reduce energy loss at the MTP joint while enhancing foot rotation as footwear 10 rotates for engagement with the ground surface during a running motion. Footwear plate 300 may define a length that extends through at least a portion of the length of sole structure 200. In some examples, the length of plate 300 extends through forefoot portion 12, midfoot portion 14, and heel portion 16 of sole structure 200. In other examples, the length of plate 300 extends through forefoot portion 12 and midfoot portion 14, but not through heel portion 16.
[0042] In some examples, the footwear plate 300 has uniform, localized stiffness (e.g., tensile strength or bending strength) throughout the entire surface area of the plate 300. The stiffness of the plate may be anisotropic, such that the stiffness in one direction across the plate differs from the stiffness in other directions. For example, the plate may be formed from at least two layers of fibers that are anisotropic with respect to each other to provide a gradient stiffness and gradient load path across the plate 300. In one configuration, the plate 300 provides greater longitudinal stiffness (e.g., along the longitudinal axis L) than transverse stiffness (e.g., transverse to the longitudinal axis L). In one example, the transverse stiffness is at least ten percent (10%) less than the longitudinal stiffness. In another example, the transverse stiffness is from about ten percent (10%) to about twenty percent (20%) of the longitudinal stiffness. In some configurations, the plate 300 is formed from one or more layers of tows of fibers and / or fiber layers including at least one of carbon fiber, aramid fiber, boron fiber, glass fiber, and polymer fiber. In specific configurations, the fibers include carbon fiber, glass fiber, or a combination of both carbon fiber and glass fiber. The fiber tows may be affixed to a substrate. The fiber tows may be affixed by stitching or with an adhesive. Additionally or alternatively, the fiber tows and / or fiber layers may be reinforced with a thermosetting polymer and / or a thermoplastic polymer. Thus, the plate 300 may have tensile or flexural strength in a transverse direction substantially perpendicular to the longitudinal axis L. The stiffness of the plate 300 may be selected for a specific wearer based on the wearer's tendon flexibility, calf muscle strength, and / or MTP joint flexibility. Additionally, the stiffness of the plate 300 may be tailored based on the athlete's running motion. In another configuration, plate 300 is formed from one or more layers / plies of unidirectional tape. In some examples, each layer in the stack includes a different orientation than the layer below it. The plate may be formed from unidirectional tape including at least one of carbon fiber, aramid fiber, boron fiber, glass fiber, and polymer fiber. In some examples, the one or more materials forming plate 300 have a Young's modulus of at least 70 gigapascals (GPa).
[0043] In some implementations, plate 300 has a substantially uniform thickness. In some instances, the thickness of plate 300 ranges from about 0.6 millimeters (mm) to about 3.0 mm. In some instances, the thickness of plate 300 is substantially equal to 1.0 mm. In other implementations, the thickness of plate 300 is non-uniform such that plate 300 may define a greater thickness in midfoot portion 14 of structure 200 than in forefoot portion 12 and heel portion 16.
[0044] The outsole 210 may include a ground-engaging surface 212 and an opposing inner surface 214. The outsole 210 may be attached to the upper 100. In some examples, the bottom surface 252 of the cushioning member 250 is attached to the inner surface 214 of the outsole, and the sidewall 230 extends from the periphery of the cushioning member 250 and is attached to the midsole 220 or the upper 100. The example of FIG. 1 shows the outsole 210 attached to the upper 100 near the tip of the forefoot portion 12. The outsole 210 generally provides abrasion resistance and traction with the ground surface during use of the article of footwear 10. The outsole 210 may be formed from one or more materials that impart durability and abrasion resistance as well as enhance traction with the ground surface. For example, rubber may form at least a portion of the outsole 210.
[0045] Midsole 220 may include a bottom surface 222 and a midsole 224 disposed on a side of midsole 220 opposite bottom surface 222. Stitching 226 or adhesive may secure midsole 220 to upper 100. Midsole 224 may be contoured to match the contours of the bottom surface (e.g., plantar) of the foot. Bottom surface 222 may face inner surface 214 of outsole 210 to define a space therebetween for receiving cushioning member 250.
[0046] 2 provides an exploded view of an article of footwear 10 showing an outsole 210, a cushioning element 250 disposed on an inner surface 214 of the outsole 210, and a substantially rigid footwear plate 300 disposed between an upper surface 254 of the cushioning element 250 and a bottom surface 222 of the midsole 220. The cushioning element 250 may be sized and shaped to occupy at least a portion of the empty space between the outsole 210 and the midsole 220, where a cavity 240 between the cushioning element 250 and the bottom surface 222 of the midsole 220 defines the remainder of the empty space that receives the footwear plate 300. Thus, the cushioning element 250 and the plate 300 may occupy substantially the entire volume of the space between the bottom surface 222 of the midsole 220 and the inner surface 214 of the outsole 210. The cushioning element 250 may be resiliently compressible between the midsole 220 and the outsole 210. In some configurations, the cushioning element 250 corresponds to a slab of polymer foam having a surface contour configured to receive the footwear plate 300 thereon. The cushioning element 250 may be formed from any suitable material that compresses resiliently under an applied load. Examples of suitable polymer materials for the foam include ethylene vinyl acetate (EVA) copolymers, polyurethanes, polyethers, and olefin block copolymers. The foam may include a single polymer material or a blend of two or more polymer materials, including polyether block amide (PEBA) copolymers, EVA copolymers, thermoplastic polyurethanes (TPUs), and / or olefin block copolymers. The cushioning element 250 has a density of approximately 0.05 grams per cubic centimeter (g / cm 3 ) to approximately 0.20 g / cm 3 In some examples, the density of the cushioning member 250 may be in the range of approximately 0.1 g / cm 3 Additionally, the dampening member 250 may comprise a hardness within a range from about 11 Shore A to about 50 Shore A. The material or materials forming the dampening member 250 may be suitable to provide an energy return of at least sixty percent (60%).
[0047] In some examples, a fluid-filled bladder 400 is disposed between the footwear plate 300 and the cushioning member 250 in at least one portion 12, 14, 16 of the sole structure 200 to enhance the cushioning characteristics of the footwear 10 in response to ground reaction forces. For example, the fluid-filled bladder 400 may define an interior cavity that receives a pressurized fluid and provides a durable, sealed boundary for retaining the pressurized fluid therein. The pressurized fluid may be air, nitrogen, helium, or a dense gas such as sulfur hexafluoride. The fluid-filled bladder may additionally or alternatively contain a liquid or gel. In other examples, the fluid-filled bladder 400 is disposed between the cushioning member 250 and the outsole 210 or between the plate 300 and the midsole 220. FIGS. 2 and 3 show a fluid-filled bladder 400 in the heel portion 16 of the sole structure 200 to help attenuate initial impact with the ground surface that occurs at the heel portion 16. In other configurations, one or more fluid-filled bladders 400 may additionally or alternatively extend through the midfoot portion 14 and / or forefoot portion 12 of sole structure 200. Cushioning member 250 and fluid-filled bladders 400 can cooperate to enhance functionality and cushioning properties when sole structure 200 is under load.
[0048] The length of the footwear plate 300 can extend between a first end 301 and a second end 302. The first end 301 can be positioned proximate the heel portion 16 of the sole structure 200, and the second end 302 can be positioned proximate the forefoot portion 12 of the sole structure 200. The first end 301 can be referred to as the "rearmost point" of the plate 300, while the second end 302 can also be referred to as the "forward-most point" of the plate. In some examples, the length of the footwear plate 300 is less than the length of the cushioning member 250. The footwear plate 300 can also have a thickness extending substantially perpendicular to the longitudinal axis L of the sole structure 200 and a width extending between the lateral portion 18 and the medial portion 20. Thus, the length, width, and thickness of plate 300 may substantially occupy cavity 240 defined by upper surface 254 of cushioning member 250 and bottom surface 222 of the midsole, and may extend through each of forefoot portion 12, midfoot portion 14, and heel portion 16 of sole structure 200. In some examples (e.g., FIG. 37 ), the peripheral edges of footwear plate 300 are found along lateral side 18 and / or medial side 20 of footwear 10.
[0049] Referring to FIG. 3 , a partial cross-sectional view taken along line 3-3 in FIG. 1 shows footwear plate 300 disposed between cushioning element 250 and midsole 220, and cushioning element 250 disposed between outsole 210 and footwear plate 300. Insole 260 may be disposed over midsole 224 within interior cavity 102 under the foot. FIG. 3 shows cushioning element 250 defining a reduced thickness to accommodate fluid-filled bladder 400 within heel region 16. In some examples, cushioning element 250 encloses bladder 400, while in other examples, cushioning element 250 merely defines a cutout for receiving bladder 400. In some configurations, a portion of plate 300 is in direct contact with fluid-filled bladder 400. Cushioning element 250 may define a greater thickness in heel portion 16 of sole structure 200 than in forefoot portion 12. Stated another way, the gap or distance separating the outsole 210 and the midsole 220 decreases in a direction from the heel portion 16 toward the forefoot portion 12 along the longitudinal axis L of the sole structure 200. In some implementations, the upper surface 254 of the cushioning member 250 is smooth and includes a surface contour that is contoured to match the surface contour of the footwear plate 300 so that the footwear plate 300 and the cushioning member 250 mate flush with one another. The cushioning member 250 may define a thickness of the sole structure at the forefoot portion 12 within a range from about 7 millimeters (mm) to about 20 mm. In one example, the thickness of the cushioning member 250 at the forefoot portion 12 is about 12 mm.
[0050] In some configurations, such as footwear 10f in FIGS. 33 and 34, spiked footwear for track running, or "track shoes," incorporates a cushioning element 250f (FIG. 34) in the forefoot portion 12 between the plate 300 and the outsole 210, which has a reduced thickness of approximately 8 mm. In these configurations, the cushioning element 250 may not be between the plate 300 and the outsole 210 in the forefoot portion 12. Additionally, cushioning material associated with the same cushioning element 250 or a different cushioning element may be positioned between the plate 300 and the midsole 220 and extend through each of the forefoot portion 12, midfoot portion 14, and heel portion 16.
[0051] Footwear plate 300 includes a curved region 310 that extends through forefoot portion 12 and midfoot portion 14 of sole structure 200. The terms "curved portion," "concave portion," and "rounded portion" may be used to describe curved region 310. Footwear plate 300 may optionally include a substantially flat region 312 that extends from curved region 310 through heel portion 16 to a rearmost point 301 of plate 300. Curved region 310 is associated with a radius of curvature centered on MTP point 320 to define a forward curved portion 322 extending from one side of MTP point 320 and a rearward curved portion 324 extending from the other side of MTP point 320. For example, the front curved portion 322 extends between the MTP point 320 and an anterior-most point (AMP) 302 (e.g., the second end 302) of the plate 300, while the back curved portion 324 extends between the MTP point 320 and a back point 326 disposed at the junction of the curved region 310 and the flat region 312. In some examples, the front curved portion 322 and the back curved portion 324 are associated with the same radius of curvature that is mirrored with respect to the MTP point 320. In other examples, the front curved portion 322 and the back curved portion 324 are each associated with a different radius of curvature. In some configurations, a portion of the back curved portion 324 is associated with the same radius of curvature as the front curved portion 322. Thus, the curved portions 322, 324 may each include corresponding radii of curvature that may be the same or different from one another. In some examples, the radii of curvature differ from one another by at least two percent (2%). The radii of curvature for the curved regions 322, 324 can range from 200 millimeters (mm) to approximately 400 mm. In some configurations, the front curved portion 322 comprises a radius of curvature that follows the curvature of the back curved portion 324 such that the curved portions 322, 324 define the same radius of curvature and share the same apex. Additionally or alternatively, the plate may define a radius of curvature that connects the back curved portion 324 to the substantially flat region 312 of the plate 300. As used herein, the term "substantially flat" refers to a flat region 312 that is within 5 degrees of horizontal, i.e., within 5 degrees of parallel to the ground.
[0052] The MTP point 320 is the point of the footwear plate 300 closest to the inner surface 214 of the outsole 210, while the rearward point 326 of the plate 300 and the AMP 302 are located farther from the outsole 210 than the MTP point 320. In some configurations, the rearward point 301 and the AMP 302 are coplanar. In some examples, the MTP point 320 of the plate 300 is located immediately below the MTP joint of the foot when the foot is received within the internal cavity 102 of the upper 100. In other examples, the MTP point 320 is located further from the toe end of the sole structure 200 than the MTP joint. The forward curved portion 322 and rearward curved portion 324 of the curved region 310 each provide longitudinal stiffness to the plate 300 to reduce energy loss in proximity to the MTP joint of the foot, and enhance foot rotation during running, thereby reducing lever arm distance and reducing stress at the ankle joint.
[0053] In some implementations, the AMP 302 and rear point 326 are located above the MTP point 320 at a distance substantially equal to a position height H, where the position height H extends from the MTP point 320 in a direction substantially perpendicular to the longitudinal axis L of the sole structure 200. The height H ranges from about 3 millimeters (mm) to about 28 mm. In another example, the height H ranges from about 3 mm to about 17 mm. In one example, the height H is equal to about 17 mm. Thus, the toes of the foot above the front curved portion 322 may be biased upward as the front curved portion 322 extends from the MTP point 320 toward the AMP 302 and away from the outsole 210. Additionally or alternatively, the length L of the front curved portion 322 may be A is the length L of the rear curved portion 324 P As used herein, L A and L P are each measured along a line extending substantially parallel to the longitudinal axis L between the MTP point 320 and one of the AMP 302 and the rear point 326. A and L P and L are each associated with the distance between the MTP point 320 and a corresponding one of the AMP 302 and the rear point 326.A and L P each equals approximately thirty percent (30%) of the total length of plate 300, while the length of flat region 312 occupies the remaining forty percent (40%) of the total length of plate 300. A is equal to about twenty-five percent (25%) to about thirty-five percent (35%) of the total length of the plate 300, and L P is equal to about twenty-five percent (25%) to about thirty-five percent (35%) of the total length of plate 300, with the length of flat region 312 equal to the remainder. A And, L P The length L of the flat region 312 is substantially equal to the length L of the curved region 310. A and L P and / or the height (H) of the forward most point 302 and the rearward point 326 relative to the MTP point 320. For example, decreasing the radius of curvature increases the angle between the MTP point 320 and the AMP 302, and also increases the height H of the AMP 302 above the MTP point 320. In configurations where the curved portions 322, 324 each have a different radius of curvature, the corresponding lengths L A and L P and / or height from MTP point 320. Accordingly, the radius of curvature of curved region 310 may vary for different shoe sizes, may vary depending on the intended use of footwear 10, and / or may vary based on the anatomical characteristics of the foot based on the wearer with wear.
[0054] In some implementations, the MTP point 320 is located approximately thirty percent (30%) of the total length of the plate from the AMP 302. The center of the radius of curvature of the curved region 310 may be located at the MTP point 320. In some examples, the curved region 310 (e.g., a recessed portion) is associated with a constant radius of curvature that extends from the AMP 302 beyond the MTP point 320. In these examples, the constant radius of curvature may extend from the AMP 302 beyond the MTP point for at least forty percent (40%) of the total length of the plate 300 from the AMP 302.
[0055] 4-6 provide an article of footwear 10a comprising upper 100 and sole structure 200a attached to upper 100. With respect to article of footwear 10a, in view of the substantial similarity in structure and function of components associated with article of footwear 10, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0056] Sole structure 200a may include outsole 210, first cushioning member 250a, footwear plate 300, second cushioning member 270, and midsole 220a arranged in a stacked configuration. Figure 5 provides an exploded view of an article of footwear 10a showing sole structure 200a (e.g., outsole 210, cushioning members 250a, 270, plate 300, midsole 220a) defining a longitudinal axis L. Outsole 210 includes an inner surface 214 disposed on a side of outsole 210 opposite ground-engaging surface 212. Midsole 220a is disposed on a side of midsole 220a opposite insole 224 and includes a bottom surface 222a facing inner surface 214 of outsole 210.
[0057] The first cushioning member 250a, the footwear plate 300, and the second cushioning member 270 are disposed between the inner surface 214 and the bottom surface 222a to separate the midsole 220a from the outsole 210. For example, the first cushioning member 250a has a bottom surface 252 that is received by the inner surface 214 of the outsole 210 and a top surface 254a that is disposed on the side of the first cushioning member 250a opposite the bottom surface 252 and faces the midsole 220a to support the footwear plate 300 thereon. The second cushioning member 270 is disposed on the side of the footwear plate 300 opposite the first cushioning member. For example, the second cushioning member 270 has a bottom surface 272 that faces the footwear plate 300 and a top surface 274 that is disposed on the side of the second cushioning member 270 opposite the bottom surface 272 and faces the bottom surface 222a of the midsole 220a. Upper surface 274 may be contoured to match the contours of the bottom surface (e.g., plantar) of the foot within interior cavity 102. Similar to cushioning member 250 of FIGS. 1-3, second cushioning member 270 may define a sidewall 230a that surrounds at least a portion of the periphery of second cushioning member 270. Sidewall 230a may define a perimeter that extends around the periphery of midsole 220a when second cushioning member 270 is attached to midsole 220a.
[0058] In some configurations, the overall thickness of each of first and second cushioning members 250a and 270 is equal to the thickness of cushioning member 250 of the article of footwear 10 of FIGS. 1-3. The thickness of first cushioning member 250a may be the same as or different from the thickness of second cushioning member 270. First and second cushioning members 250a and 270 function to embed or sandwich footwear plate 300 such that footwear plate 300 is spaced apart from both inner surface 214 of outsole 210 and bottom surface 222a of midsole 220a. Thus, cushioning members 250a, 270, and plate 300 may substantially occupy the entire volume of the space between bottom surface 222a of midsole 220a and inner surface 214 of outsole 210.
[0059] The cushioning members 250a, 270 can be elastically compressed between the midsole 220a and the outsole 210. The cushioning members 250a, 270 can each be formed from a flat plate of polymer foam, which can be formed from the same material or materials that form the cushioning member 250 of FIGS. 1-3. For example, the cushioning members 250a, 270 can be formed from one or more of EVA copolymer, polyurethane, polyether, olefin block copolymer, PEBA copolymer, and / or TPU. In some implementations, the cushioning members 250a, 270 provide different cushioning characteristics. For example, the first cushioning member 250a can be elastically compressed under an applied load to prevent the plate 300 from coming into contact with the ground surface, while the second cushioning member 270 can provide a level of softer cushioning for the wearer's foot to attenuate ground reaction forces and increase comfort for the wearer's foot. The sole structure 200a may incorporate a fluid-filled bladder 400 between the footwear plate 300 and the first cushioning member 250a in at least one portion 12, 14, 16 of the sole structure to enhance the cushioning characteristics of the footwear 10a in response to ground reaction forces. For example, the bladder 400 may be filled with a pressurized fluid, such as air, nitrogen, helium, sulfur hexafluoride, or a liquid / gel. Thus, the cushioning members 250a, 270 separated by the plate 300 and the fluid-filled bladder 400 can cooperate to provide gradient cushioning to the article of footwear 10a that varies with changes in applied load (i.e., the greater the load, the more the cushioning members 250a, 270 compress, and therefore the footwear behaves more responsively). The cushioning members 250a, 270 may have a compressibility of approximately 0.05 g / cm 3 to approximately 0.20 g / cm 3 In some examples, the density of the cushioning members 250a, 270 may range from approximately 0.1 g / cm 3 Additionally, the dampening members 250a, 270 may comprise a hardness within a range from about 11 Shore A to about 50 Shore A. The material or materials forming the dampening members 250a, 270 may be suitable to provide an energy return of at least sixty percent (60%).
[0060] Footwear plate 300 defines a length extending between first end 301 and second end 302 (e.g., AMP 302) that may be the same as or less than the length of cushioning members 250a, 270. The length, width, and thickness of plate 300 may substantially occupy the volume of space between top surface 254 of first cushioning member 250a and bottom surface 272 of second cushioning member 270 and may extend through each of forefoot portion 12, midfoot portion 14, and heel portion 16 of sole structure 200a. In some examples, plate 300 extends through forefoot portion 12 and midfoot portion 14 of sole structure 200a, but not heel portion 16. In some examples, a peripheral edge of footwear plate 300 is found along lateral side 18 and / or medial side 20 of footwear 10a. In some implementations, the top surface 254 of the first cushioning member 250a and the bottom surface 272 of the second cushioning member 270 are smooth and include surface contours that are contoured to match the surface contours of the sides of the footwear plate 300 so that the footwear plate 300 fits flush with each of the cushioning members 250a, 270.
[0061] As discussed above with reference to Figures 1-3, the footwear plate 300 may have a uniform local stiffness that may or may not be anisotropic. For example, the plate 300 may be formed from one or more layers and / or tows of fibers including at least one of carbon fiber, aramid fiber, boron fiber, glass fiber, and polymer fiber. Thus, the plate 300 may provide a greater thickness along the longitudinal direction of the sole structure than stiffness in a direction transverse (e.g., perpendicular) to the longitudinal axis L. For example, the stiffness of the plate 300 in the transverse direction may be at least 10 percent less than the stiffness of the plate 300 in the longitudinal direction, or may be approximately 10 to 20 percent of the thickness of the plate 300 along the longitudinal direction (e.g., parallel to the longitudinal axis L). Additionally, the plate 300 may have a substantially uniform thickness within a range of about 0.6 mm to about 3.0 mm across the plate 300, or a non-uniform thickness that varies across the plate, e.g., the thickness of the plate 300 in the midfoot portion 14 is greater than the thickness in the forefoot portion 12 and heel portion 16.
[0062] 6 provides a partial cross-sectional view taken along line 6-6 of FIG. 4 showing footwear plate 300 disposed between first cushioning member 250a and second cushioning member 270, with first cushioning member 250a disposed between outsole 210 and footwear plate 300 and second cushioning member 270 disposed between midsole 220a and footwear plate 300, respectively. Insole 260 may be disposed on midsole 224 within interior cavity 102 under the foot. First cushioning member 250a may enclose bladder 400 or may define a notch for receiving bladder 400, while a portion of plate 300 may be in direct contact with bladder 400. In some configurations, first cushioning member 250a defines a greater thickness in heel portion 16 of sole structure 200a than in forefoot portion 12, with upper surface 254 including a surface contour that is contoured to match the surface contour of footwear plate 300 supported thereon. Second cushioning member 270 may cooperate with first cushioning member 250a to define a space therebetween for enclosing footwear plate 300. For example, a portion of bottom surface 272 of second cushioning member 270 and a portion of upper surface 254 of first cushioning member 250a may be recessed to define a void for retaining footwear plate 300. In some implementations, the thickness of second cushioning member 270 is greater than the thickness of first cushioning member 250a in each of forefoot portion 12 and midfoot portion 14. Advantageously, the increased thickness provided by second cushioning member 270 in each of forefoot region 12 and midfoot region 14 increases the separation distance between the foot's MTP joint and footwear plate 300, thus enhancing the cushioning characteristics of footwear 10a in response to ground reaction forces when footwear 10a performs a running motion / exercise. In some configurations, second cushioning member 270 has a thickness greater than that of first cushioning member 250a at a location opposite MTP point 320 of plate 300. In these configurations, second cushioning member 270 may define a maximum thickness at a location opposite MTP point 320 of plate 300 equal to a value within a range of about 3.0 mm to about 13.0 mm. In one example, the maximum thickness is approximately equal to 10.0 mm.The thickness of the second buffer member 270 may decrease along a direction from the MTP point 320 toward the AMP 302 such that the thickness of the second buffer member 270 near the AMP 302 is approximately sixty percent (60%) less than its maximum thickness near the MTP point 320. Meanwhile, the first buffer member 250a may define a minimum thickness at a location opposite the MTP point 320 equal to a value in the range of about 0.5 mm to about 6.0 mm. In one example, the minimum thickness is equal to approximately 3.0 mm.
[0063] Footwear plate 300 includes a curved region 310 extending through forefoot portion 12 and midfoot portion 14, and may optionally include a substantially flat region 312 extending through heel portion 16 from a rear point 326 in curved region 310 to a rearmost point 301 of plate 300. The radii of curvature of curved region 310 define a forward curved portion 322 extending between MTP point 320 and AMP 302 at the toe end of sole structure 200a, and a rear curved portion 324 extending between MTP point 320 and rear point 326. In some configurations, forward curved portion 322 and rear curved portion 324 each include the same radius of curvature that is mirrored about MTP point 320. In other configurations, curved portions 322, 324 are each associated with a different radius of curvature. Accordingly, the curved portions 322, 324 may each include a corresponding radius of curvature that may be the same or different from one another. In some examples, the radii of curvature differ from one another by at least two percent (2%). The radii of curvature for the curved regions 322, 324 may range from approximately 200 millimeters (mm) to approximately 400 mm. In some configurations, the front curved portion 322 includes a radius of curvature that follows the curvature of the back curved portion 324 such that the curved portions 322, 324 define the same radius of curvature and share the same apex. Additionally or alternatively, the plate may define a radius of curvature that connects the back curved portion 324 to the substantially flat region 312 of the plate 300. As used herein, the term "substantially flat" refers to a flat region 312 that is within 5 degrees of horizontal, i.e., within 5 degrees of parallelism with the ground.
[0064] The curved regions 322, 324 may each occupy approximately thirty percent (30%) of the overall length of the plate 300, while the length of the flat region 312 may occupy the remaining forty percent (40%) of the length of the plate 300. The forward curved portion 322 and the rear curved portion 324 of the curved region 310 each provide longitudinal stiffness to the plate 300 to reduce energy loss in proximity to the MTP joint of the foot, as well as enhance foot rotation during running, thereby reducing lever arm distance and reducing stress at the ankle joint. The AMP 302 and rear point 326 may be located above the MTP point 320 at a distance substantially equal to the position height H. Additionally, the length L of the forward curved portion 322 may be approximately 40% of the total length of the plate 300. A and the length L of the rear curved portion 324 P (e.g., measured along a line extending substantially parallel to the longitudinal axis L between the MTP point 320 and each of the AMP 302 and the rear point 326) may be substantially equal to or different from one another. As discussed above with reference to FIGS. 1-3, the radius of curvature of the curved region 310 can be varied to change the length L. A and L P and / or vary the height (H) of the forward most point 302 and the rearward point 326 relative to the MTP point 320. In doing so, the stiffness of the plate 300 can be varied to provide a custom footwear plate 300 tailored to the wearer's shoe size, the intended use of the footwear 10, and / or the anatomical characteristics of the wearer's foot.
[0065] 7-9 provide an article of footwear 10b comprising upper 100 and sole structure 200b attached to upper 100. With respect to article of footwear 10b, in view of the substantial similarity in structure and function of components associated with article of footwear 10, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0066] 8 provides an exploded view of an article of footwear 10b illustrating sole structure 200b including outsole 210b, cushioning member 250b, and midsole 220b arranged in a stacked configuration and defining longitudinal axis L. Outsole 210b includes inner surface 214b disposed on a side of outsole 210b opposite ground-engaging surface 212. Midsole 220b includes bottom surface 222b disposed on a side of midsole 220b opposite insole 224. Cushioning member 250b is disposed between inner surface 214b and bottom surface 222b to separate midsole 220b from outsole 210b. For example, cushioning member 250b includes bottom surface 252b facing inner surface 214b of outsole 210b and top surface 254b facing midsole 220b and disposed on a side of cushioning member 250b opposite bottom surface 252b. Upper surface 254b may be contoured to match the contours of a bottom surface (e.g., the plantar surface of a foot) within interior cavity 102. Similar to cushioning element 250 of the article of FIGS. 1-3, cushioning element 250b may define a sidewall 230b that surrounds at least a portion of the periphery of cushioning element 250b. Sidewall 230b may define a perimeter that extends around the periphery of midsole 220b when cushioning element 250b is attached to midsole 220b.
[0067] Cushioning element 250b is resiliently compressible between midsole 220b and outsole 210b and may be formed from the same material or materials that form cushioning element 250 of FIGS. 1-3. For example, cushioning element 250b may be formed from one or more of EVA copolymer, polyurethane, polyether, olefin block copolymer, PEBA copolymer, and / or TPU. Sole structure 200b may incorporate a fluid-filled bladder 400 between footwear plate 300 and cushioning element 250b in at least one portion 12, 14, 16 of the sole structure to enhance the cushioning characteristics of footwear 10b in response to ground reaction forces. For example, bladder 400 may be filled with a pressurized fluid, such as air, nitrogen, helium, sulfur hexafluoride, or a liquid / gel.
[0068] In some configurations, the cushioning member 250b defines a cavity 240b (e.g., a sleeve) within an interior portion between the top surface 254b and the bottom surface 252b in the heel portion 16 of the sole structure 200b. FIG. 9 provides a partial cross-sectional view taken along 9-9 of FIG. 7 illustrating the substantially flat region 312 of the footwear plate 300 received within the cavity 240b of the cushioning member 250b and the curved region 310 exposed from the cavity 240b between the bottom surface 252b of the cushioning member 250b and the inner surface 214b of the outsole 210b. FIG. 9 illustrates the bottom surface 252b of the cushioning member 250b defining an access opening 242 to the cavity 240b for receiving the substantially flat portion 312 of the plate 300. The cavity 240b may be adjacent to a cutout formed in the cushioning member 250b for embedding a fluid-filled bladder 400. 7-9 includes a bottom surface 252b of cushioning member 250b that adheres to inner surface 214b of outsole 210b in heel portion 16, while curved region 310 of plate 300 that extends from cavity 240b of cushioning member 250b at access opening 242 is in direct contact with inner surface 214b in each of forefoot portion 12 and midfoot portion 14. Cavity 240b defined by cushioning member 250b thus functions to embed / enclose at least a portion of plate 300 (e.g., flat region 312). Similar to cushioning member 250 and plate 300 of FIGS. 1-3, cushioning member 250b and plate 300 can occupy substantially the entire volume of the space between bottom surface 222b of midsole 220b and inner surface 214b of outsole 210b.
[0069] Insole 260 may be positioned on midsole 224 within interior cavity 102 under the foot. Cushioning member 250b may enclose bladder 400 or may define a cutout for receiving bladder 400, while a portion of plate 300 may be in direct contact with bladder 400. The cutout for receiving bladder 400 may be adjacent cavity 240b formed through cushioning member 250b. In some configurations, cushioning member 250b defines a greater thickness in heel portion 16 of sole structure 200b than in forefoot portion 12. In some examples, the thickness of cushioning member 250b separating bottom surface 222b of midsole 220b and plate 300 is greater near curved region 310 of plate 300 than near substantially flat region 312 of plate 300. In these examples, cushioning element 250b functions to increase the separation distance between plate 300 and midsole 220b such that the MTP joint of the foot is prevented from contacting plate 300 during use of footwear 10b while performing a running motion / exercise. Cushioning element 250b may define a thickness of sole structure 200b in forefoot portion 12 within a range of about 7 millimeters (mm) to about 20 mm. In one example, cushioning element 250b in forefoot portion 12 has a thickness of about 12 mm. Cushioning element 250b has a tensile strength of about 0.05 grams per cubic centimeter (g / cm 3 ) to approximately 0.20 g / cm 3 In some examples, the density of the cushioning member 250b may be in the range of approximately 0.1 g / cm 3 Additionally, dampening member 250b may comprise a hardness within a range from about 11 Shore A to about 50 Shore A. The material or materials forming dampening member 250b may be suitable to provide an energy return of at least sixty percent (60%).
[0070] As discussed above with reference to FIGS. 1-3 , the footwear plate 300 may have a uniform local stiffness, which may or may not be anisotropic. For example, the plate 300 may be formed from one or more tows of fibers including at least one of carbon fiber, aramid fiber, boron fiber, glass fiber, and polymer fiber. Accordingly, the plate 300 may provide a greater thickness along the longitudinal direction of the sole structure than a greater stiffness in a direction transverse (e.g., perpendicular) to the longitudinal axis L. For example, the stiffness of the plate 300 in the transverse direction may be approximately 10 to 20 percent of the thickness of the plate 300 along the longitudinal direction (e.g., parallel to the longitudinal axis L). Furthermore, the plate 300 may have a substantially uniform thickness across the plate 300, ranging from about 0.6 mm to about 3.0 mm, or a non-uniform thickness that varies across the plate, e.g., the thickness of the plate 300 in the midfoot portion 14 being greater than the thickness in the forefoot portion 12 and heel portion 16. In some examples, plate 300 has a thickness equal to about 1.0 mm.
[0071] The radius of curvature of curved region 310 defines a forward curved portion 322 extending between MTP point 320 and AMP 302 at the toe end of sole structure 200b, and a rear curved portion 324 extending between MTP point 320 and rear point 326. In some configurations, front curved portion 322 and rear curved portion 324 each include the same radius of curvature that is mirrored about MTP point 320. In other configurations, curved portions 322, 324 are each associated with a different radius of curvature. Curved portions 322, 324 may each occupy approximately thirty percent (30%) of the overall length of plate 300, while the length of flat region 312 may occupy the remaining forty percent (40%) of the length of plate 300. The forward curved portion 322 and the rearward curved portion 324 of the curved region 310 each provide longitudinal stiffness to the plate 300 to reduce energy loss in proximity to the MTP joint of the foot, as well as enhance foot rotation during running, thereby reducing lever arm distance and stress at the ankle joint. The AMP 302 and the rearward point 326 are located above the MTP point 320 and may be located above the MTP point 320 at a distance substantially equal to the position height H. Additionally, the length L of the forward curved portion 322 Aand the length L of the rear curved portion 324 P (e.g., measured along a line extending substantially parallel to the longitudinal axis L between the MTP point 320 and each of the AMP 302 and the rear point 326) may be substantially equal to or different from one another. As discussed above with reference to FIGS. 1-3, the radius of curvature of the curved region 310 can be varied to change the length L. A and L P and / or vary the height (H) of the forward most point 302 and the rearward point 326 relative to the MTP point 320. In doing so, the stiffness of the plate 300 can be varied to provide a custom footwear plate 300 tailored to the wearer's shoe size, the intended use of the footwear 10, and / or the anatomical characteristics of the wearer's foot.
[0072] 10-12 provide an article of footwear 10c comprising upper 100 and sole structure 200c attached to upper 100. In view of the substantial similarity in structure and function of components associated with article of footwear 10 with respect to article of footwear 10c, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0073] 11 provides an exploded view of an article of footwear 10c illustrating sole structure 200c including outsole 210c, cushioning member 250c, and midsole 220c arranged in a stacked configuration and defining longitudinal axis L. Outsole 210c includes inner surface 214c disposed on a side of outsole 210c opposite ground-engaging surface 212. Midsole 220c includes bottom surface 222c disposed on a side of midsole 220c opposite insole 224. Cushioning member 250c is disposed between inner surface 214c and bottom surface 222c to separate midsole 220c from outsole 210c. For example, cushioning member 250c includes bottom surface 252c facing inner surface 214c of outsole 210c and top surface 254c facing midsole 220c, disposed on a side of cushioning member 250c opposite bottom surface 252c. Upper surface 254c may be contoured to match the contours of the bottom surface (e.g., plantar) of the foot within interior cavity 102. Similar to cushioning element 250 of the article of Figures 1-3, cushioning element 250c may define sidewall 230c that surrounds at least a portion of the periphery of cushioning element 250c. Sidewall 230c may define a perimeter that extends around the periphery of midsole 220c when cushioning element 250c is attached to midsole 220c.
[0074] The cushioning element 250c is resiliently compressible between the midsole 220c and the outsole 210c and may be formed from the same material or materials that form the cushioning element 250 of FIGS. 1-3. For example, the cushioning element 250c may be formed from one or more of an EVA copolymer, a polyurethane, a polyether, an olefin block copolymer, a PEBA copolymer, and / or a TPU. The sole structure 200c may incorporate a fluid-filled bladder 400 between the footwear plate 300 and the cushioning element 250c in at least one portion 12, 14, 16 of the sole structure 200c to enhance the cushioning characteristics of the footwear 10c in response to ground reaction forces. For example, the bladder 400 may be filled with a pressurized fluid, such as air, nitrogen, helium, sulfur hexafluoride, or a liquid / gel. The cushioning element 250c has a fluid density of approximately 0.05 grams per cubic centimeter (g / cm). 3 ) to approximately 0.20 g / cm 3In some examples, the density of the cushioning member 250c may be in the range of approximately 0.1 g / cm 3 Additionally, dampening member 250c may comprise a hardness within a range from about 11 Shore A to about 50 Shore A. The material or materials forming dampening member 250c may be suitable to provide an energy return of at least sixty percent (60%).
[0075] In some configurations, the cushioning member 250c defines a cavity 240c (e.g., a sleeve) within an interior portion between the upper surface 254c and the bottom surface 252c in each of the forefoot and midfoot portions 12 and 14 of the sole structure 200c. Figure 12 provides a partial cross-sectional view taken along 12-12 of Figure 10 illustrating the curved region 310 of the footwear plate 300 received within the cavity 240c of the cushioning member 250c and the substantially flat region 312 exposed from the cavity 240c between the upper surface 254c of the cushioning member 250c and the bottom surface 222c of the midsole 220c. Figure 12 illustrates the upper surface 254c of the cushioning member 250c defining an access opening 242c to the cavity 240c for receiving the curved region 310 of the plate 300. 10-12 includes an upper surface 254c of cushioning member 250c that adheres to a bottom surface 222c of midsole 220c in each of forefoot and midfoot regions 12, 14, while a substantially flat region 312 of plate 300 that extends from cavity 240c of cushioning member 250c at access opening 242c is in direct contact with bottom surface 222c in heel region 16. The entire bottom surface 252c of cushioning member 250c adheres to inner surface 214c of outsole 210c. Thus, cavity 240c defined by cushioning member 250c functions to embed / enclose at least a portion of plate 300 (e.g., curved region 310) therein. Stated another way, the curved region 310 of the plate, which supports the MTP joint of the foot, is separated from the outsole 210c and the midsole 220c by respective portions of the cushioning member 250c on either side of the cavity 240c. Similar to the cushioning member 250 and plate 300 of FIGS. 1-3 , the cushioning member 250c and plate 300 can occupy substantially the entire volume of the space between the bottom surface 222c of the midsole 220c and the inner surface 214c of the outsole 210c. The insole 260 can be positioned on the midsole 224 within the interior cavity 102 under the foot. The cushioning member 250c can enclose the bladder 400 or define a cutout for receiving the bladder 400, while a portion of the plate 300 can be in direct contact with the bladder 400. In some configurations, the cushioning member 250c defines a greater thickness in the heel portion 16 of the sole structure 200c than in the forefoot portion 12.The damping element 250c may define a thickness of the sole structure 200c in the forefoot portion 12 within a range from about 7 millimeters (mm) to about 20 mm. In one example, the thickness of the damping element 250c in the forefoot portion 12 is about 12 mm. In some implementations, the thickness of the damping element 250c between the plate 300 and the bottom surface 222c of the midsole 220c in the forefoot portion 12 is within a range from about 3 mm to about 28 mm. Additionally or alternatively, the thickness of the damping element 250c between the plate 300 and the inner surface 214c of the outsole 210c in the forefoot portion 12 is within a range from about 2 mm to about 13 mm.
[0076] As discussed above with reference to FIGS. 1-3 , the footwear plate 300 may have a uniform local stiffness, which may or may not be anisotropic. For example, the plate 300 may be formed from one or more tows of fibers including at least one of carbon fiber, aramid fiber, boron fiber, glass fiber, and polymer fiber. Accordingly, the plate 300 may provide a greater thickness along the longitudinal direction of the sole structure than a greater stiffness in a direction transverse (e.g., perpendicular) to the longitudinal axis L. For example, the stiffness of the plate 300 in the transverse direction may be approximately 10 to 20 percent of the thickness of the plate 300 along the longitudinal direction (e.g., parallel to the longitudinal axis L). Furthermore, the plate 300 may have a substantially uniform thickness across the plate 300, ranging from about 0.6 mm to about 3.0 mm, or a non-uniform thickness that varies across the plate, e.g., the thickness of the plate 300 in the midfoot portion 14 being greater than the thickness in the forefoot portion 12 and heel portion 16.
[0077] The radius of curvature of curved region 310 defines a forward curved portion 322 extending between MTP point 320 and AMP 302 at the toe end of sole structure 200a, and a rear curved portion 324 extending between MTP point 320 and rear point 326. In some configurations, front curved portion 322 and rear curved portion 324 each include the same radius of curvature mirrored about MTP point 320. In other configurations, curved portions 322, 324 are each associated with a different radius of curvature. Curved regions 322, 324 may each occupy approximately thirty percent (30%) of the overall length of plate 300, while the length of flat region 312 may occupy the remaining forty percent (40%) of the length of plate 300. The forward curved portion 322 and the rearward curved portion 324 of the curved region 310 each provide longitudinal stiffness to the plate 300 to reduce energy loss proximate the MTP joint of the foot, as well as enhance foot rotation during running, thereby reducing lever arm distance and stress at the ankle joint. In other configurations, the curved portions 322, 324 may each occupy approximately twenty-five percent (25%) to approximately thirty-five percent (35%) of the total length of the plate 300. The AMP 302 and the rearward point 326 may be located above the MTP point 320, a distance substantially equal to the position height H. Additionally, the length L of the forward curved portion 322 may be approximately 25% to 35% of the total length of the plate 300. A and the length L of the rear curved portion 324 P (e.g., measured along a line extending substantially parallel to the longitudinal axis L between the MTP point 320 and each of the AMP 302 and the rear point 326) may be substantially equal to or different from one another. As discussed above with reference to FIGS. 1-3, the radius of curvature of the curved region 310 can be varied to change the length L. A and L P and / or vary the height (H) of the forward most point 302 and the rearward point 326 relative to the MTP point 320. In doing so, the stiffness of the plate 300 can be varied to provide a custom footwear plate 300 tailored to the wearer's shoe size, the intended use of the footwear 10, and / or the anatomical characteristics of the wearer's foot.
[0078] 13-15 provide an article of footwear 10d comprising upper 100 and sole structure 200d attached to upper 100. In view of the substantial similarity in structure and function of components associated with article of footwear 10 with respect to article of footwear 10d, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0079] 14 provides an exploded view of an article of footwear 10d illustrating sole structure 200d comprising outsole 210d, cushioning member 250d, and midsole 220d arranged in a stacked configuration and defining longitudinal axis L. Outsole 210d comprises inner surface 214d disposed on a side of outsole 210d opposite ground-engaging surface 212. Midsole 220d comprises bottom surface 222d disposed on a side of midsole 220d opposite insole 224. Cushioning member 250d is disposed between inner surface 214d and bottom surface 222d to separate midsole 220d from outsole 210d. For example, cushioning member 250d comprises bottom surface 252d opposite inner surface 214d of outsole 210d and top surface 254d disposed on a side of cushioning member 250d opposite bottom surface 252d and facing midsole 220d. The upper surface 254d may be contoured to match the contours of the bottom surface (e.g., plantar) of the foot within the interior cavity 102. Similar to the cushioning member 250 of FIGS. 1-3, the cushioning member 250d may define a sidewall 230d that encircles at least a portion of the periphery of the cushioning member 250d. The sidewall 230d may define a perimeter that extends around the periphery of the midsole 220d when the cushioning member 250d is attached to the midsole 220d. The cushioning member 250d is resiliently compressible between the midsole 220d and the outsole 210d and may be formed from the same material or materials that form the cushioning member 250 of FIGS. 1-3. For example, the cushioning member 250d may be formed from one or more of an EVA copolymer, a polyurethane, a polyether, an olefin block copolymer, a PEBA copolymer, and / or TPU. The cushioning member 250d has a density of approximately 0.05 grams per cubic centimeter (g / cm).3 ) to approximately 0.20 g / cm 3 In some examples, the density of the cushioning member 250d may be in the range of approximately 0.1 g / cm 3 Additionally, cushioning member 250d may comprise a hardness within a range from about 11 Shore A to about 50 Shore A. The material or materials forming cushioning member 250d may be suitable to provide an energy return of at least sixty percent (60%).
[0080] In some configurations, cushioning member 250d defines a cavity 240d (e.g., a sleeve) within an interior portion between top surface 254d and bottom surface 252d in each of forefoot and midfoot portions 12, 14 of sole structure 200d. In this configuration, bottom surface 252d of cushioning member 250d is graduated toward top surface 254d to define a reduced thickness for cushioning member 250d in heel portion 16 compared to its thickness in each of forefoot and midfoot portions 12, 14.
[0081] 15 provides a partial cross-sectional view taken along line 15-15 of FIG. 13 illustrating the curved region 310 of footwear plate 300 received within cavity 240d of cushioning member 250d and the substantially flat region 312 exposed from cavity 240d between bottom surface 252d of cushioning member 250d and inner surface 214d of outsole 210d. While top surface 254c of cushioning member 250c in FIGS. 10-12 defines access opening 242c to cavity 240c, bottom surface 252d of cushioning member 250d defines access opening 242d to cavity 240d for receiving curved region 310 of plate 300. Thus, bottom surface 252d of cushioning member 250d adheres to inner surface 214d of outsole 210d in each of forefoot and midfoot regions 12, 14, while substantially flat region 312 of plate 300, which extends from cavity 240d of cushioning member 250d at access opening 242d formed through bottom surface 252d, is in direct contact with inner surface 214d in heel portion 16. In some examples, rear point 326 of plate 300 is disposed between curved region 310 and substantially flat region 312 and is disposed within the blended portion connecting curved region 310 to substantially flat region 312, and bottom surface 252d of cushioning member 250d is gradual upwardly toward top surface 254d adjacent the blended portion of plate 300. 15 also shows that outsole 210d gradually contacts plate 300 as bottom surface 252d of cushioning member 250d gradually transitions toward top surface 254d. For example, outsole 210d gradually transitions to contact substantially flat region 312 of plate 300 in a location proximate where plate 300 extends through access opening 242d. Thus, cavity 240d defined by cushioning member 250d functions to embed / enclose at least a portion of plate 300 (e.g., curved region 310). Stated another way, curved region 310 of the plate, which supports the MTP joint of the foot, is separated from outsole 210d and midsole 220d by respective portions of cushioning member 250d on either side of cavity 240d.Similar to the damping element 250 and plate 300 of FIGS. 1-3 , the damping element 250d and plate 300 can occupy substantially the entire volume of the space between the bottom surface 222d of the midsole 220d and the inner surface 214d of the outsole 210d. The insole 260 can be positioned under the foot on the midsole 224 within the interior cavity 102. The damping element 250d can define a thickness in the forefoot portion 12 of the sole structure 200d within a range of about 7 millimeters (mm) to about 20 mm. In one example, the thickness of the damping element 250d in the forefoot portion 12 is about 12 mm. In some implementations, the thickness of the damping element 250d between the plate 300 and the bottom surface 222d of the midsole 220d in the forefoot portion 12 is within a range of about 3 mm to about 28 mm. Additionally or alternatively, the thickness of cushioning member 250d between plate 300 and inner surface 214d of outsole 210d in forefoot portion 12 is within the range of about 2 mm to about 13 mm.
[0082] 16-18 provide a footwear plate 300a that may be incorporated into any one of the articles of footwear 10, 10a, 10b, 10c, and 10d of FIGS. 1-15 in place of footwear plate 300. With respect to footwear plate 300a, in view of the substantial similarities in structure and function of components associated with footwear plate 300, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0083] FIG. 16 provides a top perspective view of footwear plate 300a defining a length extending between first end 301, corresponding to the rearmost point of plate 300a, and second end 302, corresponding to the anterior-most point (AMP) of plate 300a. The terms "first end" and "rearmost point" are used interchangeably herein. The terms "second end" and "AMP" of plate 300a are used interchangeably herein. Footwear plate 300a may be segmented along its length to define a toe section 362, an MTP section 364, a bridge section 366, and a heel section 368. Toe section 362 corresponds to the toe of the foot, and MTP section corresponds to the MTP joints connecting the metatarsals with the phalanges of the foot. Toe section 362 and MTP section 364 of plate 300a may correspond to forefoot portions 12 of sole structures 200-200d of FIGS. 1-15. Bridge section 366 corresponds to the arch of the foot and connects MTP section 364 to heel section 368. When plate 300a is incorporated into sole structures 200-200d of Figures 1-15, bridge section 366 can correspond to midfoot portion 14, and heel section 368 can correspond to heel portion 16. Figure 16 shows footwear plate 300a including curved region 310 (including sections 362, 364, 366) and substantially flat region 312 (including section 368).
[0084] FIG. 17 provides a side view of the footwear plate 300a of FIG. 16 and shows the MTP point 320 as the closest point of the footwear plate 300a to a horizontal reference plane RP that extends substantially parallel to the ground surface (not shown). For example, the MTP point 320 may be tangent to the horizontal reference plane RP and located directly below the MTP joint of the foot when the foot is received by the interior cavity 102 of the footwear 10-10d. In another configuration, the MTP point 320 is located slightly rearward and below the MTP joint of the foot, such that the forward curved portion 322 is below the MTP joint of the foot. The forward curved portion 322 of the curved region 310 has a corresponding radius of curvature and a length L between the MTP point 320 and the AMP 302. A while the rear curved portion 324 of the curved region 310 can be defined by a corresponding radius of curvature and a length L between the MTP point 320 and the rear point 326. P As used herein, LA and L P are each measured along the horizontal reference plane RP between the MTP point 320 and one of the AMP 302 and the rear point 326. A (including toe section 362 and MTP section 364) occupies approximately thirty percent (30%) of the length of sole structure 200-200d and P The substantially flat portion 312 (including the heel section 368) occupies approximately thirty percent (30%) of the length of the sole structures 200-200d, and the substantially flat portion 312 (including the heel section 368) occupies approximately forty percent (40%) of the length of the sole structures 200-200d. A is in the range of about twenty-five percent (25%) to about thirty-five percent (35%) of the length of sole structure 200-200d, and L of rear curve portion 324 P is in the range of about twenty-five percent (25%) to about thirty-five percent (35%) of the length of sole structures 200-200d, and substantially flat region 312 includes the remainder of the length of sole structures 200-200d.
[0085] The radius of curvature associated with the forward curved portion 322 results in the AMP 302 extending from the MTP point 320 at an angle α1 relative to the horizontal reference plane RP. Accordingly, the forward curved portion 322 can bias the toe section 362 of the board 300a in a direction away from the toes of the foot. The angle α1 can include values ranging from about 12 degrees to about 35 degrees. In one example, the angle α1 includes a value approximately equal to 24 degrees. Similarly, the radius of curvature associated with the rear curved portion 324 results in the rear point 326 extending from the MTP point 320 at an angle β1 relative to the horizontal reference plane RP. The angle β1 can include values ranging from about 12 degrees to about 35 degrees. In one example, the angle β1 includes a value approximately equal to 24 degrees. In some configurations, the angles α1 and β1 are substantially equal to each other such that the radii of curvature are equal to each other and share the same vertex.
[0086] In some implementations, the rear point 326 is located along a blend portion 328 along the curved region 310 of the plate 300, the blend portion 328 including a radius of curvature configured to join the curved region 310 to the substantially flat region 312 in the rear curved portion 324. Thus, the blend portion 328 is positioned between the constant radius of curvature of the curved region 310 and the substantially flat region 312, and is positioned to connect the constant radius of curvature of the curved region 310 to the substantially flat region 312. In some examples, the blend portion includes a substantially constant radius of curvature. The blend portion 328 can extend the substantially flat region 312 of the plate in a direction substantially parallel to the horizontal reference plane RP (as well as the ground plane) between the first end 301 (the rearmost point) and the rear point 326. As a result of the radius of curvature of the rear curved portion 324 and the radius of curvature of the blend portion 328, the rear point 326 can have a height H1 above the MTP point 320. As used herein, the positional height H1 of the rear point 326 corresponds to the separation distance between the rear point 326 and the reference plane RP, extending in a direction substantially perpendicular to the horizontal reference plane RP. In some examples, the positional height H1 may include values in a range from about 3 mm to about 28 mm, while in other examples, the positional height H1 may include values in a range from about 3 mm to about 17 mm. In one example, the positional height H1 is equal to about 17 mm. In some implementations, the rearmost point 301 and the AMP 302 are coplanar at the junction of the blending portion 328 and the substantially flat region 312.
[0087] FIG. 18 provides a top view of the footwear plate 300a of FIG. 16, showing the toe section 362, MTP section 364, bridge section 366, and heel section 368 defined along the length of the plate 300a. The MTP point 320 can be located within the MTP section 364, which joins the toe section 362 to the bridge section 366. The rear point 326 can be located within the bridge section 366 at a location proximate where the bridge section 366 joins the heel section 368. For example, the radius of curvature of the fused portion 328 (FIG. 17) can seamlessly join the bridge section 366 associated with the rear curve portion 324 to the heel section 368 associated with the flat region 312 of the plate 300a.
[0088] 19-21 provide a footwear plate 300b that may be incorporated into any one of the articles of footwear 10, 10a, 10b, 10c, and 10d of Figures 1-15 in place of footwear plate 300. With respect to footwear plate 300b, in view of the substantial similarity in structure and function of components associated with footwear plate 300, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0089] Figure 19 is a top perspective view of footwear plate 300 defining a length extending between first end 301 of plate 300b and AMP 302b. Plate 300b can be sectioned along its length to define toe section 362, MTP section 364, bridge section 366, and heel section 368. Figure 19 shows footwear plate 300b including curved region 310b (including sections 362, 364, 366) and substantially flat region 312 (including section 368).
[0090] FIG. 20 provides a side view of the footwear plate 300b of FIG. 19 illustrating the MTP point 320b of the curved region 310b of the footwear plate 300b, which is tangent to the horizontal reference plane RP and positioned beneath the MTP joint of the foot when the foot is received by the interior cavity 102 of the footwear 10-10d. The forward curved portion 322b extending between the MTP point 320b and the AMP 302b includes a radius of curvature that is smaller than the radius of curvature of the forward curved portion 322 of FIGS. 16-18. Thus, the radius of curvature associated with the forward curved portion 322b results in the AMP 302b extending from the MTP point 320b at an angle α2 relative to the horizontal reference plane RP that is greater than the angle α1 associated with the forward curved portion 322 of FIGS. 16-18. Thus, the front curved portion 322b is associated with a steeper slope than the slope of the front curved portion 322 of FIGS. 16-18 such that the toe section 362 of the board 300b biases the toes of the foot farther away from the ground surface as compared to the board 300a of FIGS. 16-18. Ais in the range of about twenty-five percent (25%) to about thirty-five percent (35%) of the length of sole structure 200-200d, and L of rear curve portion 324b P is in the range of about twenty-five percent (25%) to about thirty-five percent (35%) of the length of sole structures 200-200d, and substantially flat region 312 includes the remainder of the length of sole structures 200-200d.
[0091] Similarly, the posterior curved portion 324b extending between the MTP point 320b and the posterior point 326b includes a radius of curvature that is smaller than the radius of curvature of the posterior curved portion 324 of FIGS. 16-18. Thus, the radius of curvature associated with the posterior curved portion 324b results in the posterior point 326b extending from the MTP point 320b at an angle β2 relative to the horizontal reference plane RP that is greater than the angle β1 associated with the posterior curved portion 324 of FIGS. 16-18. Thus, the posterior curved portion 324b is associated with a steeper slope than the slope of the posterior curved portion 324 of FIGS. 16-18 such that the bridge section 366 of the plate 300b biases the MTP joint of the foot toward the ground surface and further away from the heel of the foot, as compared to the plate 300a of FIGS. 16-18. The angle α2 can include values within a range from about 12 degrees to about 35 degrees. In one example, angle α2 comprises a value approximately equal to 24 degrees. Similarly, a radius of curvature associated with posterior curved portion 324b results in posterior point 326b extending from MTP point 320b at angle β2 relative to horizontal reference plane RP. Angle β2 may comprise a value within a range from about 12 degrees to about 35 degrees. In one example, angle β1 comprises a value approximately equal to 24 degrees. In some configurations, angles α2 and β2 are substantially equal to one another such that the radii of curvature are equal to one another and share the same vertex.
[0092] The curved portions 322b, 324b may each have a corresponding radius of curvature that may be the same or different from one another. In some examples, the radii of curvature differ from one another by at least two percent (2%). The radii of curvature for the curved regions 322b, 324b may range from approximately 200 millimeters (mm) to approximately 400 mm. In some configurations, the front curved portion 322b has a radius of curvature that follows the curvature of the back curved portion 324b such that the curved portions 322b, 324b define the same radius of curvature and share the same vertex. Additionally or alternatively, the plate may define a radius of curvature that connects the back curved portion 324b to the substantially flat region 312 of the plate 300b. As used herein, the term "substantially flat" refers to a flat region 312 that is within 5 degrees of horizontal, i.e., within 5 degrees of parallelism with the ground.
[0093] In some implementations, the rear point 326 is located along a blend portion 328b along the curved region 310b of the plate 300b, the blend portion 328b including a radius of curvature configured to join the curved region 310b to the substantially flat region 312 in the rear curved portion 324b. Thus, the blend portion 328b is located between the constant radius of curvature of the curved region 310b and the substantially flat region 312, and is positioned to connect the constant radius of curvature of the curved region 310b to the substantially flat region 312. In some examples, the blend portion includes a substantially constant radius of curvature. Similar to the blend portion 328 of the curved region 310 of FIGS. 16-18 , the blend portion 328b can extend the substantially flat region 312 of the plate 300b in a direction substantially parallel to the horizontal reference plane RP (as well as the ground plane) between the first end 301 (the rearmost point) and the rear point 326b. As a result of the radius of curvature of the posterior curved portion 324b and the radius of curvature of the blending portion 328b, the posterior point 326b may have a height H2 above the MTP point 320 that is greater than the height H1 of the posterior point 326 above the MTP point 320 in FIGS. 16-18. In some examples, the height H2 may include a value in the range of about 3 mm to about 28 mm, while in other examples, the height H2 may include a value in the range of about 3 mm to about 17 mm. In one example, the height H2 is equal to about 17 mm. In some implementations, the posteriormost point 301 and the AMP 302b are coplanar at the junction of the blending portion 328b and the substantially flat region 312.
[0094] FIG. 21 provides a top view of footwear plate 300b of FIG. 19, showing toe section 362, MTP section 364, bridge section 366, and heel section 368 separated along the length of plate 300b. MTP point 320b can be located within MTP section 364, which joins toe section 362 to bridge section 366. Rear point 326b can be located within bridge section 366 proximate where bridge section 366 joins heel section 368. For example, the radius of curvature of fused portion 328b (FIG. 20) can seamlessly join bridge section 366, associated with rear curve portion 324b, to heel section 368, associated with flat region 312 of plate 300b.
[0095] 22-24 provide a footwear plate 300d that may be incorporated into any one of the articles of footwear 10, 10a, 10b, 10c, and 10d of FIGS. 1-15 in place of footwear plate 300. With respect to footwear plate 300c, in view of the substantial similarity in structure and function of components associated with footwear plate 300, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0096] Figure 22 is a top perspective view of footwear plate 300c defining a length extending between first end 301 of plate 300c and AMP 302c. Plate 300c can be sectioned along its length to define toe section 362, MTP section 364, bridge section 366, and heel section 368. Figure 22 shows footwear plate 300c including curved region 310c (including sections 362, 364, 366) and substantially flat region 312 (including section 368).
[0097] FIG. 23 provides a side view of the footwear plate 300c of FIG. 22, showing that the curved region 310c is semicircular, such that the front curved portion 322c and the rear curved portion 324c are associated with the same radius of curvature R and share a common vertex V, as if the curved portions 322c, 324c were mirrored about the MTP point 320c. In some configurations, the radius R includes values within a range from about 86 mm to about 202 mm. In other configurations, the radius R includes values within a range from about 140 mm to about 160 mm. Example values for the radius R can include about 87 mm, 117 mm, 151 mm, or 201 mm. The MTP point 320c is tangent to the horizontal reference plane RP and is located below the MTP joint of the foot when the foot is received by the interior cavity 102 of the footwear 10-10d. Therefore, the MTP point 320c corresponds to the center of the curved region 310c, including the curved portions 322c, 324c. The forward curved portion 322c extends between the MTP point 320c and the AMP 302c, while the rearward curved portion 324c extends between the MTP point 320c and the rearward point 326c.
[0098] The front curved portion 322c has a length L of the rear curved portion 324c between the MTP point 320c and the rear point 326c. P Length L substantially equal to A may be defined between MTP point 320c and AMP 302c. As used herein, L A and L P are each measured along a horizontal reference plane RP between MTP point 320c and one of AMP 302c and rear point 326c. In some configurations, when footwear plate 300c is incorporated with an article of footwear 10-10d associated with men's size 10, L A and L P and L of the front curved portion 322c are each equal to approximately 81 mm. A (including toe section 362 and MTP section 364) occupies approximately thirty percent (30%) of the length of sole structure 200-200d and P The substantially flat portion 312 (including the heel section 368) occupies approximately thirty percent (30%) of the length of the sole structures 200-200d, and the substantially flat portion 312 (including the heel section 368) occupies approximately forty percent (40%) of the length of the sole structures 200-200d. A is in the range of about twenty-five percent (25%) to about thirty-five percent (35%) of the length of sole structure 200-200d, and L of rear curve portion 324c P is in the range of about twenty-five percent (25%) to about thirty-five percent (35%) of the length of sole structures 200-200d, and substantially flat region 312 includes the remainder of the length of sole structures 200-200d.
[0099] AMP 302c extends from MTP point 320c at an angle α3 relative to horizontal reference plane RP, while rear point 326c extends from MTP point 320c at an angle β3 relative to horizontal reference plane RP. Because curved portions 322c, 324c are associated with the same radius of curvature R and share a common vertex V, angles α3 and β3 are substantially equal to one another. Values of angles α3 and β3 range from about 11 degrees to about 35 degrees in other examples, and from about 20 degrees to about 25 degrees in other examples. Example values for angles α3 and β3 include about 12 degrees, 16 degrees, 22 degrees, or 57 degrees. Angle α3 corresponds to the angle at which toe section 362 of plate 300c urges the toes of a foot upward and away from the ground when the foot is received by interior cavity 102 of footwear 10-10d.
[0100] Additionally, the rear point 326c and the AMP 302c may each have the same positional height H3 above the MTP point 320c. Similar to the board 300a of FIGS. 16-18 and the board 300b of FIGS. 19-21, the positional height H3 of the rear point 326c and the MTP point 320c corresponds to a separation distance extending substantially perpendicular to the horizontal reference plane RP between the MTP point 320c and one of the rear point 326c and the AMP 302c, respectively. In some configurations, the positional height H3 includes values ranging from approximately 17 mm to approximately 57 mm. Example values for the positional height H3 may include approximately 17 mm, 24 mm, 33 mm, or 57 mm.
[0101] In some implementations, the rear point 326c is located along a blend portion 328c along the curved region 310c of the plate 300c, the blend portion 328c including a radius of curvature configured to join the curved region 310c to the substantially flat region 312 in the rear curved portion 324c. Thus, the blend portion 328c is positioned between the constant radius of curvature of the curved region 310c and the substantially flat region 312, and is positioned to connect the constant radius of curvature of the curved region 310c to the substantially flat region 312. In some examples, the blend portion includes a substantially constant radius of curvature. The blend portion 328c can extend the substantially flat region 312 of the plate 300c in a direction substantially parallel to the horizontal reference plane RP (as well as the ground plane) between the first end 301 (the rearmost point) and the rear point 326c. Thus, the AMP 302c and the rear point 326c can be substantially coplanar with the join between the blend portion 328c and the substantially flat region 312. In this manner, heel section 368 and a portion of bridge section 366 extending between first end 301 of plate 300c and rear point 326c may be substantially flat. When footwear plate 300c is incorporated with an article of footwear 10-10d associated with a men's size 10, fused portion 328c may have a radius of curvature of approximately 133.5 mm. In some implementations, rearmost point 301 and AMP 302c are coplanar at the junction of fused portion 328c and substantially flat region 312.
[0102] FIG. 24 provides a top view of footwear plate 300c of FIG. 22, showing toe section 362, MTP section 364, bridge section 366, and heel section 368 separated along the length of plate 300c. MTP point 320c can be located within MTP section 364, which joins toe section 362 to bridge section 366. Rear point 326b can be located within bridge section 366 proximate where bridge section 366 joins heel section 368. For example, the radius of curvature of fused portion 328c (FIG. 23) can seamlessly join bridge section 366, associated with rear curve portion 324c, to heel section 368, associated with flat region 312 of plate 300c. In light of the foregoing, for footwear plate 300c of FIGS. 22-24, the following parameters can be specified for a size 10 men's shoe: 1. R=201mm, α3=12 degrees, H3=17mm, L A = 81 mm, and the radius of curvature of the fused portion 328c equal to 134 mm. 2. R=151mm, α3=16 degrees, H3=24mm, L A = 81 mm, and the radius of curvature of the fused portion 328c equal to 134 mm. 3. R=117mm, α3=22 degrees, H3=33mm, L A = 81 mm, and the radius of curvature of the fused portion 328c equal to 134 mm. 4. R=87mm, α3=35 degrees, H3=57mm, L A = 81 mm, and the radius of curvature of the fused portion 328c equal to 134 mm.
[0103] 1-24, the curved region 322-c of the footwear plate 300-300c can increase the overall longitudinal stiffness of the plate 300-300c, reducing energy loss at the MTP joint of the wearer's foot while facilitating foot rotation during walking / running, thereby reducing lever arm distance and reducing strain on the wearer's ankle joint. The radius of curvature associated with the forward curved portion 322-322c particularly affects the longitudinal stiffness of the plate 300-300c and how the foot will rotate during walking / running. In some examples, the plate 300-300c excludes the substantially flat region 312 to define a length extending between the rear point 326-326c and the AMP 302-302c. The MTP point 320-320c corresponds to the point of the plate 300-300c closest to the ground (e.g., lowest) and may be located at or just posterior to the MTP joint of the foot when received by the internal cavity 102 of the footwear 10-10d above the sole structure 200-200d. One or more cushioning members 250-250c, 270 may be incorporated by the sole structure 200-200d. The cushioning members 250-250c, 270 may define a greatest thickness across the footwear plate 300-300c above the MTP point 320-320c to maximize the distance between the MTP joint of the foot and the MTP point 320-320c. The cushioning elements 250-250c, 270 may comprise a high-performance (soft, low-energy-loss) foam material that has at least 60 percent resilience when compressed under an applied load to help return energy during use of the footwear 10-10d while performing walking / running movements. Different dimensions of the footwear plates 300-300c may provide different mechanical advantages to athletes, such as runners with different running styles, e.g., forefoot strikes versus heel strikes. The radii of curvature of the curved portions 322-322c, 324-324c create different angles α1-α3, and therefore different heights H-H3 for different shoe sizes.
[0104] 25 provides a top view of footwear plate 300d that may be incorporated into any one of the articles of footwear 10, 10a, 10b, 10c, and 10d of FIGS. 1-15 in place of footwear plate 300. With respect to footwear plate 300d, in view of the substantial similarity in structure and function of components associated with footwear plate 300, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0105] Footwear plate 300d defines a length extending between first end 301 and second end 302 and is sectioned along its length to define toe section 362, MTP section 364, bridge section 366d, and heel section 368. Bridge section 366d of plate 300d defines a reduced width adjacent heel section 368 compared to the width of bridge section 366 of plates 300a, 300b, and 300c. The narrow bridge section 366d increases the flexibility of footwear plate 300d while reducing the weight of footwear plate 300d. MTP section 364 is associated with the widest portion of plate 300d, and toe section 362 is slightly narrower to support the toes of the foot.
[0106] 26, a top view of footwear plate 300e is provided that may be incorporated into any one of the articles of footwear 10, 10a, 10b, 10c, and 10d of FIGS. 1-15 in place of footwear plate 300. With respect to footwear plate 300e, in view of the substantial similarity in structure and function of components associated with footwear plate 300, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0107] 26 illustrates a footwear plate 300e lacking a heel section 368 associated with a substantially flat region 312. The plate 300e defines a reduced length extending between a first end 301e and a second end 302 and is sectioned along its length to define a toe section 362, an MTP section 364, and an interrupted bridge section 366e, where the first end 301e of the plate 300e is associated with a rear point 326-326d of the plate 300-300d.
[0108] In some examples, the interrupted bridge section 366e is associated with a reduced length sufficient to support the tarsometatarsal joints of the foot. In this manner, the plate 300e may define only a curved region 310 that includes the interrupted bridge section 366e, the MTP section 364, and the toe section 362. Additionally, the plate 300e may be formed from a single contiguous sheet of material.
[0109] 27 provides a top view of footwear plate 300f that may be incorporated into any one of the articles of footwear 10, 10a, 10b, 10c, and 10d of FIGS. 1-15 in place of footwear plate 300. With respect to footwear plate 300f, in view of the substantial similarity in structure and function of components associated with footwear plate 300, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0110] Footwear plate 300f defines a length extending through its split forefoot portion 12f, midfoot portion 14, and heel portion 16 between first end 301 and second end 302. Plate 300f includes a curved region 310 extending through split forefoot portion 12f and midfoot portion 14. Plate 300f may include a substantially flat region 312 extending from curved region 310 through heel portion 16 to first end 301 of plate 300f.
[0111] The split forefoot portion 12f of the plate 300f comprises a lateral section 371 and a medial section 372. In some examples, the lateral section 371 and the medial section 372 each extend from the MTP point 320 of the plate 300f. Dividing the forefoot portion 12f into the lateral section 371 and the medial section 372 can provide greater flexibility for the plate 300f. In some examples, the medial section 372 is wider than the lateral section 371. In one example, the medial section 372 is associated with a width suitable for supporting the first MTP bone of the foot (e.g., the big toe) and the first toe. The plate 300f can be formed from a single contiguous sheet of material.
[0112] 28 provides a top view of footwear plate 300g that may be incorporated into any one of the articles of footwear 10, 10a, 10b, 10c, and 10d of FIGS. 1-15 in place of footwear plate 300. With respect to footwear plate 300g, in view of the substantial similarity in structure and function of components associated with footwear plate 300, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0113] Footwear plate 300g defines a length extending between first end 301 and second end 302 through its toe-shaped forefoot portion 12g, midfoot portion 14, and heel portion 16. Plate 300g includes a curved region 310 extending through toe-shaped forefoot portion 12g and midfoot portion 14. Plate 300g may also include a substantially flat region 312 extending from curved region 310 through heel portion 16 to first end 301 of plate 300g.
[0114] The finger-shaped forefoot portion 12g of plate 300g includes a medial section 372g having an outer curvature 374. In some examples, medial section 372 extends from MTP point 320 of plate 300g and is associated with a width suitable for supporting the first MTP bone of the foot (e.g., the big toe). Outer curvature 374 removes portions of plate 300f that would otherwise support the second through fifth MTP bones. Plate 300g may be formed from a single contiguous sheet of material.
[0115] 29 provides a top view of footwear plate 300h that may be incorporated into any one of the articles of footwear 10, 10a, 10b, 10c, and 10d of FIGS. 1-15 in place of footwear plate 300. With respect to footwear plate 300h, in view of the substantial similarity in structure and function of components associated with footwear plate 300, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0116] Footwear plate 300h defines a length extending between first end 301 and second end 302 through its hoop-shaped forefoot portion 12h, midfoot portion 14, and heel portion 16. Plate 300h includes a curved region 310 extending through hoop-shaped forefoot portion 12h and midfoot portion 14. Plate 300h may include a substantially flat region 312 extending from curved region 310 through heel portion 16 to first end 301 of plate 300h.
[0117] The ring-shaped forefoot portion 12h of the plate 300h includes an interior cutout area 380 formed through the forefoot portion 12h of the plate 300h. The cutout area 380 is surrounded by a perimeter 382 that is bounded by the outer perimeter of the plate 300h. In some examples, the perimeter 382 extends from the MTP point 320 of the plate 300h and is configured to support the foot underneath while the interior cutout area 380 is associated with an open area to reduce the weight of the plate 300h. The plate 300h may be formed from a single contiguous sheet of material.
[0118] 30 provides a top view of footwear plate 300i that may be incorporated into any one of the articles of footwear 10, 10a, 10b, 10c, and 10d of FIGS. 1-15 in place of footwear plate 300. With respect to footwear plate 300i, in view of the substantial similarity in structure and function of components associated with footwear plate 300, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0119] Footwear plate 300i defines a length extending through its claw-shaped forefoot portion 12i, midfoot portion 14, and heel portion 16 between first end 301 and second end 302. Plate 300i includes a curved region 310 extending through claw-shaped forefoot portion 12i and midfoot portion 14. Plate 300i may include a substantially flat region 312 extending from curved region 310 through heel portion 16 to first end 301 of plate 300i.
[0120] The claw-shaped forefoot portion 12i of plate 300i includes an outer section 371i and an inner section 372i. In some examples, the outer section 371i and the inner section 372i each extend from the MTP point 320 of plate 300f. The sections 371i, 372i can cooperate to define an interior cutout area 380i that is similar to the cutout area of plate 300h of FIG. 29, except that an opening 384 separates the sections 371i, 372i, allowing the sections 371i, 372i to bend independently of one another. Thus, claw-shaped forefoot portion 12i provides outer and inner sections 371i and 372i that can flex independently of one another, similar to sections 371, 372 of split forefoot portion 12f, except that interior cutout area 380i provides plate 300i with a reduced weight compared to the weight of plate 300f incorporating split forefoot portion 12f of Figure 27. Plate 300i may be formed from a single adjacent sheet of material.
[0121] 31 and 32 provide an article of footwear 10e comprising upper 100 and sole structure 200e attached to upper 100. In view of the substantial similarity in structure and function of components associated with article of footwear 10e, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0122] Sole structure 200e includes outsole 210e, cushioning member 250e, footwear plate 300, and midsole 220e arranged in a laminated configuration. FIG. 32 provides a partial cross-sectional view taken along line 32-32 of FIG. 31 and shows footwear plate 300 disposed between cushioning member 250e and midsole 220e in each of midfoot portion 14 and heel portion 16, and between outsole 210e and midsole 220e in forefoot portion 12. Cushioning member 250e includes a bottom surface 252e facing the ground surface 2 and a top surface 254e disposed on a side of cushioning member 250e opposite bottom surface 252e and secured to plate 300. Outsole 210e can correspond to one or more ground-contacting sections that can be secured to bottom surface 252e of cushioning member 250e and plate 300. In some configurations, the outsole 210e is omitted such that the bottom surface 252e of the cushioning member 250e contacts the ground surface 2 in each of the midfoot and heel portions 14, 16 of the sole structure 200e, and the plate 300 contacts the ground surface 2 in the forefoot portion 12 of the sole structure 200e, i.e., in the curved region 310 of the plate 300.
[0123] In some implementations, one or more projections 800 (e.g., track spikes) extend from the plate 300 and outsole 210e toward the ground surface 2 to provide traction. The projections 800 can be directly attached to the plate 300 or outsole 210e. FIG. 32 illustrates that no cushioning material is located above the MTP point 320 (e.g., between the plate 300 and the midsole 220e) or below the MTP point 320 (e.g., between the plate 300 and the outsole 210e). Thus, cushioning material 250e is provided in each of the midfoot portion 14 and the heel portion 16 to attenuate the initial impact of ground reaction forces during a running motion, while cushioning material 250e is absent from the forefoot portion 12, where cushioning is less essential, to reduce the weight of the sole structure 200e. An exemplary footwear 10e incorporating the sole structure 200e may be associated with a track shoe for shorter distance track events. Additionally, an insole 260 may be positioned under the foot within the interior cavity 102 on the inner sole 224 of the midsole 220e.
[0124] 33 and 34 provide an article of footwear 10f comprising upper 100 and sole structure 200f attached to upper 100. In view of the substantial similarity in structure and function of components associated with article of footwear 10 with respect to article of footwear 10f, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0125] Sole structure 200f may include outsole 210f, cushioning member 250f, footwear plate 300, and midsole 220f arranged in a laminated configuration. FIG. 34 provides a partial cross-sectional view taken along line 34-34 of FIG. 33 and shows footwear plate 300 disposed between cushioning member 250f and midsole 220f, and cushioning member 250f disposed between plate 300 and outsole 210f and / or ground surface 2. Cushioning member 250f includes a bottom surface 252f facing the ground surface 2 and a top surface 254f disposed on a side of cushioning member 250f opposite bottom surface 252f and secured to plate 300. Outsole 210f may correspond to one or more ground-contacting sections that may be secured to bottom surface 252f of cushioning member 250f. In some configurations, the outsole 210f is omitted such that the bottom surface 252f of the cushioning member 250f contacts the ground surface 2. Additionally, an insole 260 can be positioned over the insole 224 of the midsole 220f within the interior cavity 102 under the foot.
[0126] The cushioning member 250f may define a greater thickness in the heel portion 16 of the sole structure 200f than in the forefoot portion 12. Stated another way, the gap or distance separating the outsole 210f and the midsole 220f decreases in a direction from the heel portion 16 toward the forefoot portion 12 along the longitudinal axis L of the sole structure 200f. In some implementations, the upper surface 254f of the cushioning member 250f is smooth and includes a contoured surface that matches the surface contour of the footwear plate 300 so that the footwear plate 300 and the cushioning member 250f mate flush with one another. The cushioning member 250f may define a thickness in the forefoot portion 12 of the sole structure within a range of 8 mm to approximately 9 mm. Accordingly, the thickness of the cushioning member 250f opposite the curved region 310 of the plate 300 may be thick enough to prevent the plate 300 from directly contacting the ground surface 2 during a running motion.
[0127] In some implementations, one or more protrusions 800 (e.g., track spikes) extend from the plate 300 and outsole 210f in a direction toward the ground surface 2 to provide traction. The protrusions 800 can be attached directly to the plate 300, the cushioning member 250f, or the outsole 210f.
[0128] 35 and 36 provide an article of footwear 10g comprising an upper and a sole structure 200g attached to upper 100. With respect to article of footwear 10g, in light of the substantial similarity in structure and function of components associated with article of footwear 10, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0129] 35 provides a top perspective view of an article of footwear 10g, showing sole structure 200g comprising outsole 210g, cushioning member 250g, footwear plate 300, and midsole 220g arranged in a layered configuration and defining longitudinal axis L. In some configurations, the peripheral edges of footwear plate 300 are visible from the exterior of footwear 10g along each of lateral side 18 and medial side 20. In these configurations, footwear 10g may be designed for intended use for walking.
[0130] FIG. 36 provides a partial cross-sectional view taken along line 36-36 of FIG. 35, showing footwear plate 300 disposed between cushioning member 250g and midsole 220g, and cushioning member 250g disposed between plate 300 and outsole 210g. Insole 260 may be disposed on midsole 224 within interior cavity 102 under the foot. Although not included in the configuration of FIG. 36, fluid-filled bladder 400 of FIGS. 1-3 may be incorporated with sole structure 200g to provide additional cushioning. Outsole 210g includes ground-engaging surface 212g and inner surface 214g disposed on the side of outsole 210g opposite ground-engaging surface 212g and facing bottom surface 252g of cushioning member 250g. Cushioning member 250g includes bottom surface 252g and top surface 254g disposed on the side of cushioning member 250g opposite bottom surface 252g.
[0131] The configuration of sole structure 200g is substantially identical to sole structure 200 of FIGS. 1-3 , except that sole structure 200g includes a plurality of openings 255 formed through outsole 210g and cushioning member 250g to expose a portion of plate 300 when viewed from the bottom of footwear 10g. FIG. 36 illustrates a plurality of openings 255 located in heel portion 16 and forefoot portion 12. Other configurations may include more / fewer openings 255 in heel portion 16 and / or forefoot portion 12, or may include openings in midfoot portion 14. In some implementations, only one of portions 12, 14, 16 includes openings 255. Each opening 255 may be formed through outsole 210g and cushioning member 250g and may extend in a direction substantially perpendicular to longitudinal axis L. Advantageously, apertures 255 function to reduce the overall weight of sole structure 200g to provide a lighter 10g article of footwear. Apertures 255 may similarly be formed through any of sole structures 200-200f of Figures 1-15 and 33-36.
[0132] 37-39 provide an article of footwear 10h comprising upper 100 and sole structure 200h attached to upper 100. In view of the substantial similarity in structure and function of components associated with article of footwear 10 with respect to article of footwear 10h, like numerals are used hereinafter and in the drawings to identify like components, while like numerals with letter extensions are used to identify modified components.
[0133] Sole structure 200h includes outsole 210, first cushioning member 250h, a plate formed from fluid-filled bladder 400h, and midsole 220h arranged in a laminated configuration. Figure 38 provides an exploded view of an article of footwear 10h showing sole structure 200h (e.g., outsole 210h, cushioning member 250h, midsole 220h) defining longitudinal axis L. Outsole 210h includes an inner surface 214h disposed on a side of outsole 210h opposite ground-engaging surface 212. Midsole 220h includes a bottom surface 222h disposed on a side of midsole 220h opposite midsole 224 and facing inner surface 214h of outsole 210h.
[0134] The cushioning element 250h and the fluid-filled bladder 400h are disposed between the inner surface 214h and the bottom surface 222h to separate the midsole 220h from the outsole 210h. For example, the cushioning element 250h includes a bottom surface 252 that is received by the inner surface 214h of the outsole 210h, and an upper surface 254h that is disposed on the side of the cushioning element 250h opposite the bottom surface 252 and faces the midsole 220h to support the bladder 400h. In some examples, a sidewall 230h surrounds at least a portion of the periphery of the cushioning element 250h and separates the cushioning element 250h from the midsole 220h to define a cavity 240h therebetween. For example, the sidewall 230h may define a periphery around at least a portion of the periphery of the contoured upper surface 254h of the cushioning element 250h to encase the foot during use of the footwear 10 when performing a walking or running motion. The perimeter may extend around the periphery of the midsole 220h when the cushioning member 250h is attached to the midsole 220h.
[0135] In some configurations, the fluid-filled bladder 400h is positioned below the midsole 220h on the upper surface 254h of the cushioning member 250h to reduce energy loss at the MTP joint while enhancing foot rotation as the footwear 10h rotates to engage the ground surface during a running motion. Similar to the footwear plate 300 of FIGS. 1-3 , the fluid-filled bladder 400h has a stiffness greater than the stiffness of the cushioning member 250h and the outsole 210h. The fluid-filled bladder 400h may define a length that extends through at least a portion of the length of the sole structure 200h. In some examples, the length of the bladder 400h extends through the forefoot portion 12, the midfoot portion 14, and the heel portion 16 of the sole structure 200h. In other examples, the length of the bladder 400h extends through the forefoot portion 12 and the midfoot portion 14, but not through the heel portion 16.
[0136] The cushioning element 250h may be resiliently compressible between the midsole 220h and the outsole 210h. The cushioning element 250h may be formed from a slab of polymer foam, which may be formed from the same material or materials that form the cushioning element 250 of FIGS. 1-3. For example, the cushioning element 250h may be formed from one or more of EVA copolymer, polyurethane, polyether, olefin block copolymer, PEBA copolymer, and / or TPU. The fluid-filled bladder 400h may enhance the cushioning characteristics of the footwear 10h in response to ground reaction forces. For example, the bladder 400h may be filled with a pressurized fluid, such as air, nitrogen, helium, sulfur hexafluoride, or a liquid / gel.
[0137] The length of the fluid-filled bladder 400h may be the same as or shorter than the length of the cushioning member 250h. The length, width, and thickness of the bladder 400h may substantially occupy the volume of the space (e.g., cavity 240h) between the top surface 254h of the cushioning member 250h and the bottom surface 222h of the midsole 220h, and may extend through each of the forefoot portion 12, midfoot portion 14, and heel portion 16 of the sole structure 200h. In some examples, the bladder 400h extends through the forefoot portion 12 and midfoot portion 14 of the sole structure 200h, but not in the heel portion 16. In some examples, the sidewall 403 of the bladder 400h is found along the lateral portion 18 and / or medial portion 20 of the footwear 10h. In some implementations, the top surface 254h of the cushioning member 250h and the bottom surface 222h of the midsole 220h are smooth and include surface contours that are contoured to match the surface contours of the sides of the bladder 400h so that the bladder 400h fits flush with the cushioning member 250h and the midsole 220h.
[0138] The fluid-filled bladder 400h defines an interior cavity that receives pressurized fluid and provides a durable, sealed boundary for retaining the pressurized fluid therein. The bladder 400h may include an upper boundary portion 401 that faces the bottom surface 222h of the midsole 220h and a lower boundary portion 402 that is disposed on the side of the bladder 400h opposite the upper boundary portion 401 and faces the top surface 254h of the cushioning member 250h. A sidewall 403 extends around the perimeter of the bladder 400h and connects the upper boundary portion 401 to the lower boundary portion 402.
[0139] In some configurations, the interior cavity of the fluid-filled bladder 400h also receives a tether element 500 having an upper plate attached to the upper boundary portion 401, a lower plate attached to the lower boundary portion 402, and a plurality of tethers 530 extending between the upper and lower plates. Adhesive or thermal bonding may be used to secure the tether element 500 to the bladder 400h. The tether element 500 functions to prevent the bladder 400h from expanding or widening outward due to the pressure of the fluid within the interior cavity of the bladder 400h. That is, the tether element 500 can limit the expansion of the bladder 400h when under pressure in order to maintain the intended shape of the surfaces of the boundary portions 401 and 402.
[0140] Figure 39 provides a partial cross-sectional view taken along line 39-39 of Figure 37 and shows a fluid-filled bladder 400h disposed between cushioning member 250h and midsole 220h, and cushioning member 250h disposed between outsole 210h and bladder 400h. Insole 260 may be positioned over midsole 224 within interior cavity 102 under the foot. In some configurations, cushioning member 250h defines a greater thickness in the heel portion of sole structure 200h than in the forefoot portion 12, and upper surface 254h includes a surface contour that is contoured to match the surface contour of lower boundary portion 402 of bladder 400h therein. Cushioning member 250h may cooperate with midsole 220h to define a space therebetween for enclosing bladder 400h.
[0141] Similar to footwear plates 300-300i, bladder 400h includes a curved region 410 extending through forefoot portion 12 and midfoot portion 14, and may optionally include a substantially flat region 412 extending through heel portion 16 from a rear point in curved region 410 to an AMP of bladder 400h located proximate the toe end of sole structure 200h. The curved region may have radii of curvature defining forward curved portion 422 and rear curved portion 424 that are similar to the corresponding forward curved portion 322 and rear curved portion 324 of footwear plate 300 of FIGS. 1-3. In some configurations, curved portions 422, 424 each have the same radius of curvature mirrored with respect to MTP point 420 associated with a point of bladder 400h located closest to outsole 210h. In other configurations, curved portions 422, 424 are each associated with a different radius of curvature. The curved portions 422, 424 may each occupy approximately thirty percent (30%) of the total length of the bladder 400h, while the length of the flat region 412 may occupy the remaining forty percent (40%) of the length of the bladder 400h. The forward curved portion 422 and rearward curved portion 424 of the curved region 410 each provide longitudinal stiffness to the bladder 400h that reduces energy loss near the MTP joint of the foot, while enhancing foot rotation during running, thereby reducing lever arm distance and stress at the ankle joint. While the example footwear 10h of Figures 37-39 incorporates a curved fluid-filled bladder 400h between the cushioning member 250h and the midsole 220h in place of the footwear plate 300, the curved fluid-filled bladder 400h may also replace the plate 300 in any of the previously described articles of footwear 10-10g.
[0142] The aforementioned footwear plates 300-300i may be manufactured using fiber sheets or fabrics, including pre-impregnated (i.e., "prepreg") fiber sheets or fabrics. Alternatively or additionally, the footwear plates 300-300i may be manufactured with strands formed from multiple filaments of one or more types of fiber (e.g., fiber tows) by fastening the fiber tows to a substrate or to each other to create a plate having fiber strands arranged primarily at predetermined angles or in predetermined positions. When fiber strands are used, the fiber types included in the strands include synthetic polymer fibers that can be melted and resolidified to solidify other fibers present in the strands and, optionally, other components, such as sewing threads or the substrate, or both. Alternatively or additionally, the fibers of the strands and, optionally, other components, such as sewing threads or the substrate, or both, may be solidified by applying a resin after fastening the fiber strands to the substrate and / or to each other. These processes are described below.
[0143] Referring to FIGS. 40A-40E and 41, footwear plates 300-300i are shown formed using a series of overlapping prepreg fiber sheets 600a-600e. Prepreg fiber sheets 600a-600e can be formed from the same or different materials. For example, each of sheets 600a-600e can be a unidirectional tape or a multiaxial weave having a series of fibers 602 impregnated with resin. Fibers 602 can include at least one of carbon fiber, aramid fiber, boron fiber, glass fiber, and other polymer fibers forming the unidirectional sheet or multiaxial weave. Fibers such as carbon fiber, aramid fiber, and boron fiber can provide a high Young's modulus, while glass fiber (e.g., fiberglass) and other polymer fibers (e.g., synthetic fibers such as aramid, polyester, and polyamides other than polyolefins) provide a moderate Young's modulus. Alternatively, some of the sheets 600a-600e may be unidirectional tapes, while other of the sheets 600a-600e may be multiaxial woven fabrics. Further, each of the sheets 600a-600e may include fibers 602 formed from the same material, or one or more of the sheets 600a-600e may include fibers 602 formed from a different material than the fibers 602 of the other sheets 600a-600e.
[0144] During the manufacture of the boards 300-300i, a unidirectional tape or multiaxial fabric is provided and cut into fiber plies. The plies are cut and angled relative to one another, and the various sheet shapes 600a-600e are cut from the stacked plies into the shapes shown in Figures 40A-40E. In doing so, the sheets 600a-600e comprise fibers 602 formed at different angles relative to one another, such that the longitudinal axes of the fibers 602 of the unidirectional tape or multiaxial fabric are positioned at an angle (Φ) relative to the longitudinal axis (L) of each sheet 600a-600e upon cutting. Thus, when the sheets 600a-600e are stacked relative to one another, the longitudinal axes of the fibers 602 are positioned at different angles relative to the longitudinal axis of the boards 300-300i.
[0145] In the position configuration, the angle (Φ) shown in Figure 40A is zero degrees (0°), the angle (Φ) shown in Figure 40B is -15 degrees (-15°), the angle (Φ) shown in Figure 40C is -30 degrees (-30°), the angle (Φ) shown in Figure 40D is 15 degrees (15°), and the angle (Φ) shown in Figure 40E is 30 degrees (30°). When manufacturing boards 300-300i, the plies are stacked such that when sheets 600a-600e are cut from the stacked plies, the sheets 600a-600e have the shapes shown in Figures 40A-40E and are stacked in the order shown in Figure 41. That is, the bottom sheet 600c includes fibers 602 positioned at -30° relative to the longitudinal axis (L), the next sheet 600d includes fibers positioned at 15° relative to the longitudinal axis (L), the next two sheets 600a include fibers positioned at 0° relative to the longitudinal axis (L), the next sheet 600b includes fibers positioned at -15° relative to the longitudinal axis (L), and the topmost and final sheet 600e includes fibers 602 positioned at 30° relative to the longitudinal axis (L). Although the bottom sheet 600c is described as being positioned at a -30° angle (Φ) relative to the longitudinal axis (L) and the top sheet 600e is described as being positioned at a 30° angle (Φ) relative to the longitudinal axis (L), the bottom sheet 600c may alternatively be positioned at a -15° angle (Φ) relative to the longitudinal axis (L) and the top sheet 600e may alternatively be positioned at a 15° angle (Φ) relative to the longitudinal axis (L). Additionally, although two sheets 600a are described as being disposed at a 0° angle (Φ) relative to the longitudinal axis (L), three or more sheets 600a may be provided at a 0° angle (Φ). For example, eight sheets 600a may be provided.
[0146] Once the plies are stacked and cut into sheets 600a-600e, the stacks are subjected to heat and pressure to impart the particular shape of the plates 300-300i to the stacked sheets 600a-600e, as described in more detail below. Additionally, when fibers pre-impregnated with resin are used, exposing the stacks to heat and pressure can melt or soften the pre-impregnated resin, securing the plies together and holding them in a particular shape. Alternatively or additionally, a liquid resin may be applied to the plies to secure the plates together and, in some cases, to harden the fibers, thereby increasing the tensile strength of the plate when the resin solidifies.
[0147] 42A-42E and 43, footwear plates 300-300i are shown formed using a process of securing fiber strands to a substrate. That is, footwear plates 300-300i are formed from one or more fiber strands 702 arranged in a pattern selected to impart anisotropic stiffness and gradient load paths throughout the plate 300-300i. The fiber strands 702 may be secured to the same or separate substrates 704 and embroidered in a stacked configuration. When fiber strands 702 are applied to separate substrates 704, the individual substrates 704 are layered on top of each other as each substrate 704 is provided with a fiber strand 702. On the other hand, if only one substrate 704 is utilized in forming the plates 300-300i, a first strand of fiber 702 is applied to the substrate 704, with additional strands 702 (i.e., layers) of fiber being applied atop the first strand 702. Finally, a single continuous strand of fiber 702 may be used to form the plates 300-300i, whereby the strand 702 is first applied and secured to the substrate 704, and then laminated upon itself to form the laminated structure shown in FIG. 43. While each of the foregoing steps can be used to form the plates 300-300i, the following steps are described as using a single substrate 704 with individual strands of fiber 702 applied to form the structure shown in FIG. 43, whereby the individual strands 702a-702e form the layers 700a-700e of the preformed plate, respectively.
[0148] Each strand 702 can refer to a tow of multiple fibers, a monofilament, a thread, or a pre-impregnated tow of polymer. For example, strand 702 can include a plurality of carbon fibers and a plurality of resin fibers that, when activated, solidify and hold the carbon fibers in a desired shape and position relative to one another. As used herein, the term "tow" refers to a bundle (i.e., a plurality of filaments (e.g., fibers) that may or may not be twisted), and each tow can be designated by a size associated with the quantity of fibers it contains. For example, a single strand 702 can range in size from approximately 1,000 fibers per bundle to approximately 48,000 fibers per bundle. As used herein, substrate 704 refers to any one of a veil, carrier, or backing material to which at least one strand of fiber 702 is attached. The substrate 704 can be formed from a thermoset or thermoplastic material and can be a fabric (e.g., knit, woven, or nonwoven), injection molded, or thermoformed. In some configurations, the fibers associated with the strands 702 include at least one of carbon fibers, aramid fibers, boron fibers, glass fibers, and polymer fibers. Fibers such as carbon fibers, aramid fibers, and boron fibers can provide a large Young's modulus, while glass fibers (e.g., fiberglass) and polymer fibers (e.g., synthetic fibers) provide a moderate Young's modulus.
[0149] When forming plates 300-300i, first strands 702c can be applied to substrate 704. That is, first strands 702c can be applied directly to substrate 704 and stitched to substrate 704 to hold first strands 702c in a desired location. In a position configuration, first strands 702c are applied to substrate 704 so as to be positioned at an angle (Φ) shown in FIG. 42C as being negative thirty degrees (-30°) relative to the longitudinal axis (L) of substrate 704. Another strand 702d, or second strand 702d, can be applied to first strand 702c, for example via stitching, and formed at an angle (Φ) shown in FIG. 42B as being negative fifteen degrees (-15°) relative to the longitudinal axis (L) of substrate 704. The third strand 702a may be applied to the second strand at an angle (Φ) shown in Figure 42A as being zero degrees (0°) relative to the longitudinal axis (L) of the substrate 704. The fourth strand 702b may be applied to the third strand at an angle (Φ) shown in Figure 42D as being fifteen degrees (15°) relative to the longitudinal axis (L) of the substrate 704. The fifth and final strand 702e may be applied to the fourth strand at an angle (Φ) shown in Figure 42E as being thirty degrees (30°) relative to the longitudinal axis (L) of the substrate 704. Although the first strand 702c is shown and described as being applied at an angle (Φ) shown in FIG. 42C as being −30 degrees (−30°) relative to the longitudinal axis (L) of the substrate 704, and the fifth strand 702e is shown and described as being applied at an angle (Φ) shown in FIG. 42E as being 30 degrees (30°) relative to the longitudinal axis (L) of the substrate 704, these angles (Φ) may instead be −15 degrees (−15°) and 15 degrees (15°), respectively.
[0150] The strands 702a-702e form the various layers 700a-700e of the preformed boards 300-300i. Once formed, the layers 700a-700e are subjected to heat and pressure, as described in more detail below, to activate the resin impregnated in the various strands 702a-702e and also to impart the specific shape of the boards 300-300i to the layers 700a-700e.
[0151] As previously discussed, the boards 300-300i formed using the lamination process (FIG. 43) include one less layer than the boards 300-300i formed via prepreg fiber sheets (FIG. 41). That is, the lamination process may utilize only one ply 700a, which has an angle (Φ) shown in FIG. 42A as being zero degrees (0°) relative to the longitudinal axis (L) of the substrate 704. Although the lamination process uses one less ply when forming the boards 300-300i, the resulting boards 300-300i have substantially the same properties (i.e., stiffness, thickness, etc.) as the boards 300-300i formed using prepreg fiber sheets.
[0152] 44 and 45, the formation of plates 300-300c will be described in combination with a mold 800. Mold 800 includes a first mold half 802 and a second mold half 804. Mold halves 802, 804 include a mold cavity 806 having the shape of one of the various plates 300-300i such that mold 800 can impart the desired shape of a particular plate 300-300i to stacked sheets 600a-600e or to layers 700a-700e.
[0153] After forming the stacked sheets 600a-600e or layers 700a-700e, the sheets 600a-600e or layers 700a-700e are inserted between mold halves 802, 804 within mold cavity 806. At this point, mold 800 is closed by moving mold halves 802, 804 toward each other or by moving one of the mold halves 802, 804 toward the other of the mold halves 802, 804. Once closed, mold 800 applies heat and pressure to the stacked sheets 600a-600e or layers 700a-700e disposed within mold cavity 806 to activate the resin associated with the stacked sheets 600a-600e or layers 700a-700e. The heat and pressure applied to the stacked sheets 600a-600e or layers 700a-700e causes the stacked sheets 600a-600e or layers 700a-700e to adopt the specific shape of the mold cavity 806, and once cured, the resin associated with the stacked sheets 600a-600e or layers 700a-700e causes the stacked sheets 600a-600e or layers 700a-700e to harden and retain the desired shape.
[0154] It should be noted that although sheets 600a-600e and layers 700a-700e are described as including a resin material, sheets 600a-600e and layers 700a-700e may additionally be provided with resin that is infused into mold 800. The infused resin may be in addition to the resin impregnated in sheets 600a-600e and layers 700a-700e, or alternatively, may be used in place of the resin that is impregnated.
[0155] The above-described process may be used to form footwear plates and cushioning elements that can be used to manufacture customized footwear. For example, various measurements of the foot may be recorded to determine appropriate dimensions for the footwear plates and cushioning elements to be incorporated into the article of footwear. Data associated with the foot entry may also be obtained to determine whether the foot exhibits a toe strike or a heel strike. The foot measurements and obtained data may be used to determine the optimal angle and radius of curvature of the footwear plate and the thickness of one or more cushioning elements positioned above or below the cushioning element or encapsulating the footwear plate. Furthermore, the length and width of the footwear plate may be determined based on the collected data and the foot measurements. In some examples, the foot measurements and collected data are used to select a footwear plate and / or cushioning element that closely matches the wearer's foot from a plurality of pre-fabricated footwear plates and / or cushioning elements of various sizes and dimensions.
[0156] Custom footwear plates can further enable tailoring of plate stiffness for a specific wearer of the footwear. For example, an athlete's tendon stiffness and calf muscle strength can be measured to determine the appropriate stiffness of the plate for use by the athlete. Here, the stiffness of the footwear plate can vary with the athlete's strength or to the size / condition of the athlete's tendons. Additionally or alternatively, the stiffness of the plate may be tailored based on the specific athlete's biomechanics and running mechanics, such as how the athlete's joint angles change during a running motion. In some examples, measurements of the athlete's forces and kinematics are obtained before manufacturing a custom plate for the athlete. In other examples, plates are manufactured with specific ranges or increments of stiffness to provide a semi-custom footwear so that individual athletes can select the appropriate stiffness.
[0157] In some examples, a method of manufacturing footwear plate 300 includes providing a plurality of overlapping plies (or toes), fusing the plurality of overlapping plies to form a unitary layer, and thermally forming the unitary layer to form plate 300. The method may include providing upper 100 defining interior void 102 and inserting the plate into interior void 102. The method may include providing midsole 220 extending from forefoot portion 12 to heel portion 16, positioning plate 300 over a portion of midsole 220, securing upper 100 to midsole 220, and securing outsole 210 to midsole 220 to form the article of footwear.
[0158] The following clauses provide exemplary constructions for plates for the aforementioned articles of footwear.
[0159] Clause 1: A sole structure for an article of footwear having an upper, the sole structure comprising: an outsole; and a plate disposed between the outsole and the upper. The plate comprises: a forward-most point disposed in a forefoot region of the sole structure; a rearward-most point disposed closer to the heel region of the sole structure than the forward-most point; and a recessed portion extending between the forward-most point and the rearward-most point and including a constant radius of curvature from the forward-most point to a metatarsophalangeal (MTP) point of the sole structure, the MTP point facing the metatarsophalangeal (MTP) joint of the foot during use. A first cushioning layer may be disposed between the recessed portion and the upper.
[0160] Clause 2: The sole structure of clause 1, wherein the forward most point and the rearward most point are coplanar.
[0161] Clause 3: The sole structure of clause 2, wherein the plate comprises a substantially flat portion disposed in a heel region of the sole structure, the rearmost point being located within the substantially flat portion.
[0162] Clause 4: The sole structure of clause 1, wherein the plate comprises a substantially flat portion disposed in a heel region of the sole structure, the rearmost point being located within the substantially flat portion.
[0163] Clause 5: The sole structure of clause 4, further comprising a fused portion disposed between the recessed portion and the substantially flat portion and connecting the recessed portion and the substantially flat portion.
[0164] Clause 6: The sole structure of clause 5, wherein the fused portion includes a substantially constant curvature.
[0165] Clause 7: The sole structure of clause 5, wherein the fused portion comprises a radius of curvature equal to approximately 134 millimeters (mm) for a men's size 10 article of footwear.
[0166] Clause 8: The sole structure of clause 5, wherein the forward-most point and the rearward-most point are coplanar at the junction of the fused portion and the substantially flat portion.
[0167] Clause 9: The sole structure of any one of clauses 3 to 8, further comprising a second cushioning layer disposed between the substantially flat portion and the upper.
[0168] Clause 10: The sole structure of clause 9, further comprising a third cushioning layer disposed between the outsole and the board.
[0169] Clause 11: The sole structure of clause 10, wherein the third cushioning layer is disposed in the heel region.
[0170] Clause 12: The sole structure of clause 10, wherein the third cushioning layer extends from the heel region to the forefoot region.
[0171] Clause 13: A sole structure as described in Clause 12, wherein the second cushioning member has a thickness of from about 3.0 millimeters (mm) to about 13.0 mm at a location opposite the MTP point, and the third cushioning member has a thickness of from about 0.5 mm to about 6.0 mm at a location opposite the MTP point.
[0172] Clause 14: At least one of the first cushioning element, the second cushioning element, and the third cushioning element has a density of about 0.05 grams per cubic centimeter (g / cm 3) to approximately 0.20 g / cm 3 13. The sole structure of any one of clauses 9 to 12, comprising a density of from about 11 Shore A to about 50 Shore A, a hardness of from about 11 Shore A to about 50 Shore A, and a return of energy of at least sixty percent (60%).
[0173] Clause 15: A sole structure according to any one of clauses 9 to 12, further comprising at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate.
[0174] Clause 16: The sole structure of clause 15, wherein the at least one fluid-filled chamber is disposed within at least one of the second cushioning layer and the third cushioning layer.
[0175] Clause 17: The sole structure of any one of clauses 1 to 16, wherein the MTP point is located approximately thirty percent (30%) of the total length of the board from the forward most point and the rearmost point is located approximately thirty percent (30%) of the total length of the board from the MTP point.
[0176] Clause 18: A sole structure as described in any one of clauses 1 to 17, wherein the MTP point is located approximately eighty-one millimeters (81 mm) of the full length of the board from the forward-most point and the rearmost point is located approximately eighty-one millimeters (81 mm) of the full length of the board from the forward-most point.
[0177] Clause 19: The sole structure of any one of clauses 1 to 18, wherein the MTP point is located between about twenty-five percent (25%) and about thirty-five percent (35%) of the total length of the board from the forward-most point, and the rear-most point is located between about twenty-five percent (25%) and about thirty-five percent (35%) of the total length of the board from the MTP point.
[0178] Clause 20: The sole structure of any one of clauses 1 to 19, wherein the center of the radius of curvature is located at the MTP point.
[0179] Clause 21: The sole structure of any one of clauses 1 to 20, wherein the constant radius of curvature extends from the forward-most point beyond the MTP point.
[0180] Clause 22: The sole structure of clause 1, wherein the constant radius of curvature extends from the forward most point beyond the MTP point for at least forty percent (40%) of the total length of the board from the forward most point.
[0181] Clause 23: A sole structure described in any one of clauses 1 to 22, wherein the outsole comprises a ground contact surface and an inner surface formed on a side of the outsole opposite the ground contact surface, the inner surface being directly attached to the plate.
[0182] Clause 24: The sole structure of clause 23, wherein the inner surface is attached to the board adjacent the recessed portion.
[0183] Clause 25: The sole structure of any one of clauses 1 to 24, wherein the plate has a thickness of from about 0.6 millimeters (mm) to about 3.0 mm.
[0184] Clause 26: The sole structure of any one of clauses 1 to 25, wherein the plate has a Young's modulus at least equal to 70 gigapascals (GPa).
[0185] Clause 27: The sole structure of any one of clauses 1 to 26, wherein the forward most point and the rearmost point of the board each have a height from the MTP equal to about 3 mm to about 28 mm.
[0186] Clause 28: The sole structure of any one of clauses 1 to 27, wherein the forward-most point and the rearward-most point of the board each have a positional height from the MTP equal to about 17 millimeters (mm) to about 57 mm.
[0187] Clause 29: The sole structure of any one of clauses 1 to 28, wherein the forward-most point extends from the MTP point at an angle of from about 12 degrees to about 35 degrees relative to a horizontal reference plane.
[0188] Clause 30: The sole structure of any one of clauses 1 to 29, wherein the rearmost point extends from the MTP point at an angle of from about 12 degrees to about 35 degrees relative to a horizontal reference plane.
[0189] Clause 31: A sole structure for an article of footwear having an upper, the sole structure comprising: an outsole; and a plate disposed between the outsole and the upper. The plate comprises: a forward-most point disposed in a forefoot region of the sole structure; a rearward-most point disposed closer to the heel region of the sole structure than the forward-most point; and a curved portion extending between the forward-most point and the rearward-most point, connecting the forward-most point and the rearward-most point, the curved portion including a constant radius of curvature from the forward-most point to a metatarsophalangeal (MTP) point of the sole structure, the MTP point facing the MTP joint of the foot in use. A first cushioning layer may be disposed between the curved portion and the upper.
[0190] Clause 32: The sole structure of clause 31, wherein the forward most point and the rearward most point are coplanar.
[0191] Clause 33: The sole structure of clause 32, wherein the plate comprises a substantially flat portion disposed in a heel region of the sole structure, the rearmost point being located within the substantially flat portion.
[0192] Clause 34: The sole structure of clause 31, wherein the plate comprises a substantially flat portion disposed in a heel region of the sole structure, the rearmost point being located within the substantially flat portion.
[0193] Clause 35: The sole structure of Clause 34, further comprising a fused portion disposed between the recessed portion and the substantially flat portion, connecting the curved portion and the substantially flat portion.
[0194] Clause 36: The sole structure of Clause 35, wherein the fused portion includes a substantially constant curvature.
[0195] Clause 37: The sole structure of clause 24, wherein the fused portion comprises a radius of curvature equal to approximately 134 millimeters (mm) for a men's size 10 article of footwear.
[0196] Clause 38: The sole structure of Clause 35, wherein the forward most point and the rearward most point are coplanar at the junction of the fused portion and the substantially flat portion.
[0197] Clause 39: The sole structure of any one of clauses 33 to 38, further comprising a second cushioning layer disposed between the substantially flat portion and the upper.
[0198] Clause 40: The sole structure of clause 39, further comprising a third cushioning layer disposed between the outsole and the board.
[0199] Clause 41: The sole structure of clause 40, wherein the third cushioning layer is positioned in the heel region.
[0200] Clause 42: The sole structure of clause 40, wherein the third cushioning layer extends from the heel region to the forefoot region.
[0201] Clause 43: A sole structure as described in Clause 42, wherein the second cushioning member has a thickness of from about 3.0 millimeters (mm) to about 13.0 mm at a location opposite the MTP point, and the third cushioning member has a thickness of from about 0.5 mm to about 6.0 mm at a location opposite the MTP point.
[0202] Clause 44: At least one of the first cushioning member, the second cushioning member, and the third cushioning member has a tensile strength of about 0.05 grams per cubic centimeter (g / cm 3 ) to approximately 0.20 g / cm 3 44. The sole structure of any one of clauses 39-43, comprising a density of from about 11 Shore A to about 50 Shore A, a hardness of from about 11 Shore A to about 50 Shore A, and a return of energy of at least sixty percent (60%).
[0203] Clause 45: A sole structure according to any one of clauses 39 to 42, further comprising at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate.
[0204] Clause 46: The sole structure of Clause 45, wherein at least one fluid-filled chamber is disposed within at least one of the second cushioning layer and the third cushioning layer.
[0205] Clause 47: The sole structure of any one of clauses 31 to 46, wherein the MTP point is located approximately thirty percent (30%) of the total length of the board from the forward most point and the rearmost point is located approximately thirty percent (30%) of the total length of the board from the MTP point.
[0206] Clause 48: A sole structure as described in any one of clauses 31 to 47, wherein the MTP point is located approximately eighty-one millimeters (81 mm) of the full length of the board from the forward most point and the rearmost point is located approximately eighty-one millimeters (81 mm) of the full length of the board from the forward most point.
[0207] Clause 49: The sole structure of any one of clauses 31 to 48, wherein the MTP point is located between about twenty-five percent (25%) and about thirty-five percent (35%) of the total length of the board from the forward-most point, and the rear-most point is located between about twenty-five percent (25%) and about thirty-five percent (35%) of the total length of the board from the MTP point.
[0208] Clause 50: The sole structure of any one of clauses 31 to 49, wherein the center of the radius of curvature is located at the MTP point.
[0209] Clause 51: The sole structure of any one of clauses 31 to 50, wherein the constant radius of curvature extends from the forward most point beyond the MTP point.
[0210] Clause 52: The sole structure of Clause 31, wherein the constant radius of curvature extends from the forward most point beyond the MTP point for at least forty percent (40%) of the total length of the board from the forward most point.
[0211] Clause 53: A sole structure according to any one of clauses 31 to 52, wherein the outsole comprises a ground contact surface and an inner surface formed on a side of the outsole opposite the ground contact surface, the inner surface being directly attached to the plate.
[0212] Clause 54: The sole structure of Clause 53, wherein the inner surface is attached to the board adjacent the curved portion.
[0213] Clause 55: The sole structure of any one of clauses 31 to 54, wherein the plate has a thickness of from about 0.6 millimeters (mm) to about 3.0 mm.
[0214] Clause 56: The sole structure of any one of clauses 31 to 55, wherein the plate has a Young's modulus at least equal to 70 gigapascals (GPa).
[0215] Clause 57: The sole structure of any one of clauses 31 to 56, wherein the forward most point and the rearmost point of the board each have a height from the MTP equal to about 3 mm to about 28 mm.
[0216] Clause 58: The sole structure of any one of clauses 31 to 57, wherein the forward most point and the rearmost point of the board each have a positional height from the MTP equal to about 17 millimeters (mm) to about 57 mm.
[0217] Clause 59: The sole structure of any one of clauses 31 to 58, wherein the forward-most point extends from the MTP point at an angle of from about 12 degrees to about 35 degrees relative to a horizontal reference plane.
[0218] Clause 60: The sole structure of any one of clauses 31 to 59, wherein the rearmost point extends from the MTP point at an angle of from about 12 degrees to about 35 degrees relative to a horizontal reference plane.
[0219] Clause 61: A sole structure for an article of footwear having an upper, the sole structure comprising: an outsole; and a plate disposed between the outsole and the upper. The plate comprises: a forward-most point disposed in a forefoot region of the sole structure; a rearward-most point disposed closer to the heel region of the sole structure than the forward-most point; and a curved portion extending between the forward-most point and the rearward-most point, connecting the forward-most point and the rearward-most point, and including a circular curve from the forward-most point to a metatarsophalangeal (MTP) point of the sole structure, the MTP point facing the metatarsophalangeal (MTP) joint of the foot in use. A first cushioning layer may be disposed between the curved portion and the upper.
[0220] Clause 62: The sole structure of clause 61, wherein the forward most point and the rearward most point are coplanar.
[0221] Clause 63: The sole structure of Clause 62, wherein the plate comprises a substantially flat portion disposed in a heel region of the sole structure, the rearmost point being located within the substantially flat portion.
[0222] Clause 64: The sole structure of Clause 61, wherein the plate comprises a substantially flat portion disposed in a heel region of the sole structure, the rearmost point being located within the substantially flat portion.
[0223] Clause 65: The sole structure of Clause 64, further comprising a fused portion disposed between the recessed portion and the substantially flat portion, connecting the curved portion and the substantially flat portion.
[0224] Clause 66: The sole structure of Clause 65, wherein the fused portion includes a substantially constant curvature.
[0225] Clause 67: The sole structure of clause 65, wherein the fused portion has a radius of curvature equal to approximately 134 millimeters (mm) for a men's size 10 article of footwear.
[0226] Clause 68: The sole structure of Clause 65, wherein the forward most point and the rearward most point are coplanar at the junction of the fused portion and the substantially flat portion.
[0227] Clause 69: A sole structure described in any one of clauses 63 to 68, further comprising a second cushioning layer disposed between the substantially flat portion and the upper.
[0228] Clause 70: The sole structure of clause 69, further comprising a third cushioning layer disposed between the outsole and the board.
[0229] Clause 71: The sole structure of clause 70, wherein the third cushioning layer is positioned in the heel region.
[0230] Clause 72: The sole structure of Clause 70, wherein the third cushioning layer extends from the heel region to the forefoot region.
[0231] Clause 73: A sole structure as described in Clause 72, wherein the second cushioning member has a thickness of from about 3.0 millimeters (mm) to about 13.0 mm at a location opposite the MTP point, and the third cushioning member has a thickness of from about 0.5 mm to about 6.0 mm at a location opposite the MTP point.
[0232] Clause 74: At least one of the first cushioning member, the second cushioning member, and the third cushioning member has a density of about 0.05 grams per cubic centimeter (g / cm 3 ) to approximately 0.20 g / cm 3 74. The sole structure of any one of clauses 69-73, comprising a density of from about 11 Shore A to about 50 Shore A, a hardness of from about 11 Shore A to about 50 Shore A, and a return of energy of at least sixty percent (60%).
[0233] Clause 75: A sole structure according to any one of clauses 69 to 72, further comprising at least one fluid-filled chamber disposed between the plate and the upper and / or between the outsole and the plate.
[0234] Clause 76: The sole structure of Clause 75, wherein at least one fluid-filled chamber is disposed within at least one of the second cushioning layer and the third cushioning layer.
[0235] Clause 77: A sole structure as described in any one of clauses 61 to 76, wherein the MTP point is located approximately thirty percent (30%) of the total length of the board from the forward most point and the rearmost point is located approximately thirty percent (30%) of the total length of the board from the MTP point.
[0236] Clause 78: A sole structure as described in any one of clauses 61 to 77, wherein the MTP point is located approximately eighty-one millimeters (81 mm) of the full length of the board from the forward most point and the rearmost point is located approximately eighty-one millimeters (81 mm) of the full length of the board from the forward most point.
[0237] Clause 79: A sole structure as described in any one of clauses 61 to 78, wherein the MTP point is located between about twenty-five percent (25%) and about thirty-five percent (35%) of the total length of the board from the forward-most point, and the rear-most point is located between about twenty-five percent (25%) and about thirty-five percent (35%) of the total length of the board from the MTP point.
[0238] Clause 80: The sole structure of any one of clauses 61 to 79, wherein the center of circular curvature is located at the MTP point.
[0239] Clause 81: The sole structure of any one of clauses 61 to 80, wherein the circular curvature extends from the forward most point beyond the MTP point.
[0240] Clause 82: The sole structure of clause 61, wherein the circular curvature extends from the forward most point beyond the MTP point for at least forty percent (40%) of the total length of the board from the forward most point.
[0241] Clause 83: A sole structure according to any one of clauses 61 to 82, wherein the outsole comprises a ground contact surface and an inner surface formed on a side of the outsole opposite the ground contact surface, the inner surface being directly attached to the plate.
[0242] Clause 84: The sole structure of Clause 83, wherein the inner surface is attached to the plate adjacent the curved portion.
[0243] Clause 85: The sole structure of Clause 83, further comprising a second cushioning layer disposed on a side of the plate opposite the first cushioning layer and forming at least a portion of the outsole.
[0244] Clause 86: The sole structure of any one of clauses 61 to 85, wherein the plate has a thickness of from about 0.6 millimeters (mm) to about 3.0 mm.
[0245] Clause 87: The sole structure of any one of clauses 61 to 86, wherein the plate has a Young's modulus equal to at least 70 gigapascals (GPa).
[0246] Clause 88: The sole structure of any one of clauses 61 to 87, wherein the forward most point and the rearmost point of the board each have a positional height from the MTP equal to about 3 mm to about 28 mm.
[0247] Clause 89: The sole structure of any one of clauses 61 to 88, wherein the forward most point and the rearmost point of the board each have a positional height from the MTP equal to about 17 millimeters (mm) to about 57 mm.
[0248] Clause 90: The sole structure of any one of clauses 61 to 89, wherein the forward-most point extends from the MTP point at an angle of from about 12 degrees to about 35 degrees relative to a horizontal reference plane.
[0249] Clause 91: The sole structure of any one of clauses 61 to 90, wherein the rearmost point extends from the MTP point at an angle of from about 12 degrees to about 35 degrees relative to a horizontal reference plane.
[0250] Clause 92: A method of manufacturing an article of footwear, comprising receiving a sole structure according to any one of clauses 1 to 91, receiving an upper for the article of footwear, and securing the sole structure and the upper to one another.
[0251] Clause 93: A method of making any of the sole structures of clauses 1 to 91, comprising overlapping fiber sheets to form a plate of any of the sole structures of clauses 1 to 91.
[0252] Clause 94: The method of clause 93, further comprising applying heat and pressure to the overlapped fibrous sheets to activate the resin associated with the fibrous sheets.
[0253] Clause 95: The method of clause 94, wherein applying heat and pressure includes applying heat and pressure in a mold.
[0254] Clause 96: A method of making any of the sole structures of clauses 1 to 91, comprising applying a first tow of fibre to a first substrate to form a plate of any of the sole structures of clauses 1 to 91.
[0255] Clause 97: The method of clause 96, further comprising applying a second tow of fibers to the first tow of fibers to form a board.
[0256] Clause 98: The method of clause 96, further comprising applying a second tow of fibers to a second substrate and stacking the first substrate and the second substrate together with the first tow of fibers and the second tow of fibers to form a plate.
[0257] Clause 99: The method of clause 96, further comprising applying heat and pressure to the fibers to activate the resin associated with the fiber sheet.
[0258] Clause 100: The method of clause 99, wherein applying heat and pressure includes applying heat and pressure in a mold.
[0259] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular configuration are not generally limited to that particular configuration and, where applicable, may be substituted for one another and used in selected configurations, even when not explicitly shown or described. The same may be varied in many ways. Such variations are not to be construed as departures from the present disclosure, and all such variations are intended to be included within the scope of the present disclosure. [Explanation of symbols]
[0260] 2 Ground surface 10, 10a, 10b, 10c, 10d, 10e, 10f, 10g Footwear 12 Forefoot area 12f split front leg part 12g finger-shaped forefoot part 12h ring-shaped forefoot part 12i Claw-shaped front legs 14 Midfoot 16 Heel area 18 Outer part 20 Inner part 100 Upper 102 Vacant Space 104 Ankle Opening 106 Fasteners 110 Tongue part 200, 200a, 200b, 200c, 200d, 200e, 200f, 200g, 200h Sole structure 210, 210b, 210c, 210d, 210e, 210f, 210g, 210h outsole 212, 212g ground engagement surface 214, 214b, 214c, 214d, 214g inner surface 220, 220a, 220b, 220c, 220d, 220e, 220f, 220g, 220h midsole 222, 222a, 222b, 222c, 222d, 222h bottom 224 Insole 226 Sewing 230, 230a, 230b, 230c, 230d, 230h side wall 240, 240b, 240c, 240d, 240h hollow 242, 242c, 242d access openings 250, 250f, 250b, 250c, 250d, 250e, 250f, 250g, 250h Cushioning material 250a, 250h First buffer member 252, 252b, 252c, 252d, 252e, 252f, 252g bottom 254, 254a, 254b, 254c, 254d, 254e, 254f, 254g, 254h top 255 Aperture 260 insole 270 Second buffer member 272 bottom 274 Top surface 300, 300a, 300b, 300c, 300d, 300e, 300f, 300g, 300h, 300i footwear 301, 301e First end, rearmost point 302, 302b, 302c Second end, forward most point, AMP 310, 310b, 310c curved regions 312 Substantially flat area, substantially flat portion 320, 320b, 320c MTP points 322, 322b, 322c Front curved portion, curved region 324, 324b, 324c Back curved portion, curved region 326, 326b, 326c, 326d rear points 328, 328b, 328c fusion part 362 Toe Section 364 MTP classification 366, 366d, 366e Bridge Division 368 Heel classification 371, 371i outer division 372, 372g, 372i inner division 374 Outer Curvature 380, 380i internal cutout area 382 Periphery 384 Aperture 400 fluid filling bag 401 Upper boundary part 402 Lower boundary part 403 Side wall 410 Curved Area 412 Virtually Flat Area 420 MTP points 422 Front curved part 424 Rear curved part 500 Tether Elements 530 Tether 600a, 600b, 600c, 600d, 600e prepreg fiber sheet 602 Fiber 700a, 700b, 700c, 700d, 700e layers 702 Strand 702a Third Strand 702b Fourth Strand 702c 1st Strand 702d Second Strand 702e 5th and 6th Strands 704 Base material 800 protrusions 800 mold 802 First mold half 804 Second mold half 806 mold cavity H, H1, H2, H3 position height L longitudinal axis L A Length of the forward curve L P Length of the rear curve R radius of curvature RP Horizontal Reference Plane V Vertex α1, α2, α3 angle β1, β2, β3 angles Φ angle
Claims
1. 1. A sole structure for an article of footwear having an upper including an interior surface defining an interior void, the sole structure having a forefoot region, a midfoot region, and a heel region, the sole structure comprising: a plate including: (i) a curved region disposed in the forefoot region and the midfoot region, the curved region having a constant radius of curvature extending from a forward-most point to a fusion portion, the curved region having a first surface defining a concave portion and a second surface disposed opposite the curved region from the first surface and defining a convex portion; and (ii) a substantially flat region extending from the fusion portion through the heel region of the sole structure; a first cushioning member disposed between the first surface of the plate and the upper, the first cushioning member including a first section disposed between the curved region and the upper in the forefoot region of the sole structure and a second section disposed between the substantially flat region of the plate and the upper in the heel region of the sole structure; a second cushioning member disposed between the second surface of the plate and a ground contact surface of the sole structure, the second cushioning member being disposed between the flex region and the ground contact surface in the forefoot region and including a third section having a thickness less than a thickness of the first section; and the first and second cushioning members extend from the forefoot region to the heel region; The plate has a greater stiffness than the first and second cushioning members.
2. the second cushioning member includes a fourth section disposed between the plate and the ground contact surface of the midfoot region and the heel region of the sole structure; The sole structure of claim 1 .
3. the fourth section comprises a thickness greater than the third section; The sole structure of claim 2.
4. The fourth section in the heel region includes a thickness greater than the first section. The sole structure of claim 2.
5. the plate is disposed between the first buffer member and the second buffer member; The sole structure of claim 1 .
6. The first buffer member and the second buffer member are formed from a foam material. The sole structure of claim 1 .
7. 1. A sole structure for an article of footwear having an upper including an interior surface defining an interior void, the sole structure having a forefoot region, a midfoot region, and a heel region, the sole structure comprising: a board including a curved region disposed in the forefoot region and the midfoot region, the curved region having a first surface defining a concave portion and a second surface disposed on an opposite side of the board from the first surface and defining a convex portion; a first cushioning member disposed between the first surface of the plate and the upper, the first cushioning member including a first section disposed between the flex region and the upper in the forefoot region of the sole structure, and a second section disposed between the plate and the upper in the midfoot region of the sole structure; a second cushioning member disposed on the second side of the plate toward the ground contact surface of the sole structure, the second cushioning member including a third section disposed between the curved region and the ground contact surface of the forefoot region, and a fourth section disposed between the plate and the ground contact surface of the midfoot region, the third section having a thickness less than a thickness of the first section; and the first and second cushioning members extend from the forefoot region to the heel region; the plate has a greater rigidity than the first buffer member and the second buffer member; The plate is substantially flat in the heel region and extends substantially along the entire length of the sole structure from a forward end of the sole structure to a rearward end of the sole structure.
8. the fourth section comprises a thickness greater than the third section; The sole structure of claim 7.
9. The fourth section near the heel region includes a thickness greater than the second section. The sole structure of claim 7.
10. the plate is disposed between the first buffer member and the second buffer member; The sole structure of claim 7.
11. The first buffer member and the second buffer member are formed from a foam material. The sole structure of claim 7.
12. An article of footwear incorporating the sole structure of claim 1.
Citation Information
Patent Citations
Shoe sole for health
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Footwear structure and method of forming the same
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