Footwear made from industrial wood

Abstract

The footwear includes an upper and a sole structure defining a forefoot region, a midfoot region, and a heel region, the sole structure including densified wood and including an upper midsole cushioning member, a lower midsole cushioning member, an outsole coupled to a bottom surface of the lower midsole cushioning member, and a plate disposed between the upper midsole cushioning member and the lower midsole cushioning member.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to footwear that includes densified wood therein. [Background technology]

[0002] Many conventional shoes or other footwear generally include an upper and a sole attached to the lower end of the upper. Conventional shoes also include an interior space—i.e., a void or cavity formed by the upper and the interior surface of the sole—that accommodates the user's foot before the shoe is secured to the foot. The sole is attached to the underside or boundary of the upper and is positioned between the upper and the ground. As a result, the sole typically provides stability and cushioning to the user when the shoe is worn. In some examples, the sole may include multiple components, such as an outsole, a midsole, and an insole. The outsole can provide traction to the bottom surface of the sole, and the midsole can be attached to the inner surface of the outsole and provide cushioning or added stability to the sole. For example, the sole may include a specific foam material that can increase stability at one or more desired locations along the sole, or a foam material that can reduce stress or impact energy on the foot or leg when the user is running, walking, or engaging in another activity. The sole may also include additional components, such as an embedded plate, to increase the overall rigidity of the sole and reduce energy loss during use.

[0003] The upper generally defines an internal cavity that extends upward from the sole and completely or partially encases the foot. In most cases, the upper extends across the instep and toe regions of the foot, as well as across the medial and lateral sides. Many footwear articles may also include a tongue that extends across the instep region, defines an opening into the cavity, and bridges the gap between the medial and lateral edges of the upper. The tongue may also be positioned below the lacing system and between the medial and lateral sides of the upper to allow adjustment of the shoe's tightness. The tongue may also be further operable by the user to allow the foot to enter or exit the internal space or cavity. In addition, the lacing system allows the user to adjust specific dimensions of the upper or sole, thereby allowing the upper to accommodate a wide variety of foot types having different sizes and shapes.

[0004] The upper may include a variety of materials, which may be selected based on one or more intended uses of the shoe. The upper may also include portions that include various materials specific to specific regions of the upper. For example, additional stability may be desired in the forefoot or adjacent heel regions of the upper to provide a higher degree of resistance or rigidity. In contrast, other portions of the shoe may include soft woven fabrics to provide areas that are stretch-resistant, flexible, breathable, or moisture-wicking.

[0005] However, while many currently available shoes have various features related to the above properties, many shoes, and their sole structures, may be further optimized to provide targeted support to a user's feet to aid in stability while running, walking, or engaging in strenuous athletic activities. In addition, many shoes, and their sole structures, may be further optimized to provide targeted support to a user's feet to reduce energy dissipation and thereby increase a user's efficiency during physical activities such as running. Summary of the Invention [Problem to be solved by the invention]

[0006] Therefore, footwear characterized by providing such benefits across regions of the foot is desirable. These and other deficiencies of the prior art are outlined in the following disclosure. [Means for solving the problem]

[0007] The footwear described herein may have various configurations. The footwear may include densified wood and have an upper and a sole structure. The sole structure may define a toe region, a midfoot region, and a heel region. The sole structure may further include an upper midsole cushioning member, a lower midsole cushioning member, and an outsole coupled to a bottom surface of the lower midsole cushioning member. The sole structure may further include a plate disposed between the upper midsole cushioning member and the lower cushioning member. Part or all of the sole structure may include densified wood.

[0008] In some embodiments, the plate may include a curved portion and a flat portion. In these embodiments, the curved portion may include a forward curved portion extending through at least the forefoot region of the footwear and a rearward curved portion extending through the midfoot region of the footwear and at least a portion of the heel region of the footwear. In further embodiments, the plate may be constructed from densified wood. Additionally, the forward curved portion may include a split first segment and a split second segment.

[0009] In further embodiments, the sole structure may also include a heel support structure in a heel region of the footwear, and the heel support structure may be constructed from thermoplastic polyurethane. In some embodiments, the upper midsole cushioning member and the lower cushioning member are each foamed materials. For example, in certain embodiments, the foamed material is formed from a material selected from the group consisting of ethylene vinyl acetate, thermoplastic polyurethane, thermoplastic elastomer, and mixtures thereof. In yet other embodiments, the foamed material is formed during a supercritical foaming process or a physical foaming process, which may include nitrogen, carbon dioxide, supercritical nitrogen, or supercritical carbon dioxide.

[0010] In certain embodiments, the front curved portion is angled at an angle between about 5 degrees and about 45 degrees relative to the reference plane, the back curved portion is angled at an angle between about 3 degrees and about 45 degrees relative to the reference plane, and the flat portion is angled at an angle between about 0 degrees and about 5 degrees relative to the reference plane.

[0011] In some embodiments, the densified wood has a density of about 1.4 g / cc to about 1.6 g / cc. In some embodiments, the densified wood panel has been delignified to remove at least 30% of the lignin relative to the lignin content of the natural wood prior to delignification. In some embodiments, the densified wood panel has been treated with chemicals to enhance hydrophobicity, weather resistance, corrosion resistance, or flame resistance.

[0012] In a further embodiment, the densified wood is made by a process comprising contacting natural wood containing lignin and cellulose with a sodium-based chemical solution for a time and under conditions sufficient to form delignified wood, and compressing the delignified wood until its thickness is reduced by at least 40%. In a specific embodiment, the sodium-based chemical solution is selected from the group consisting of NaOH, NaOH / Na2S, NaHSO3+SO2+H2O, NaHSCb, NaHSO3+Na2SO3, NaOH+Na2SO3, Na2SO3, NaOH+AQ, NaOH / Na2S+AQ, NaHSO3+SO2+H2O+AQ, NaOH+Na2SO3+AQ, NaHSO3+Na2SO3+AQ, Na2SO3+AQ, NaOH+Na2S+Na2S n , Na2SO3 + NaOH + CH3OH + AQ, C2H5OH + NaOH, NaClO, NaClO2 + acetic acid, or combinations thereof, where n is an integer and AQ is anthraquinone. In certain embodiments, the delignified wood is compressed at a pressure of 0.5 MPa to 10 MPa. In certain embodiments, the delignified wood is compressed at a temperature of about 100°F to about 250°F.

[0013] In some embodiments, densified wood is made by viscoelastic thermocompression of natural wood.

[0014] In another embodiment of the present disclosure, a piece of footwear is provided that includes an upper and a sole structure. In this embodiment, the sole structure includes a sole plate that includes densified wood, and the sole plate includes one or more protrusions. In some embodiments, a stud is attached to each of the one or more protrusions. In certain embodiments, the stud is formed from a metal, rubber, or thermoplastic material.

[0015] In another embodiment of the present disclosure, footwear is provided that includes an upper and a sole structure. In this embodiment, the sole structure may define a toe region, a midfoot region, and a heel region, and the sole structure may include a midsole cushioning member, an outsole coupled to a bottom surface of the midsole cushioning member, and a densified wood plate. The plate may also include a toe section, an arch section, and a rear segment. Furthermore, in these embodiments, the toe section and the arch section are disposed between the midsole cushioning member and the outsole, and the rear segment is disposed above the midsole cushioning member.

[0016] In some embodiments, the midsole cushioning member includes an opening, and a portion of the plate between the rear segment and the arch portion extends between the opening in the midsole cushioning member. The sole structure may further include a heel cushioning member and a heel support collar. In further embodiments, the plate may include a forward curved portion, an inner curved portion, a rear curved portion, and a flat portion. The forward curved portion, the inner curved portion, the rear curved portion, and the flat portion may each be angled relative to a reference plane.

[0017] In yet another embodiment, the present disclosure provides footwear having an upper and a sole structure coupled to the upper. In this embodiment, the sole structure may define a toe region, a midfoot region, and a heel region. The sole structure may further include an upper midsole cushioning member, a lower midsole cushioning member, an outsole coupled between a bottom surface of the lower midsole cushioning member, and a plate including densified wood disposed between the upper midsole cushioning member and the lower midsole cushioning member. In these embodiments, the upper midsole cushioning member and the lower midsole cushioning member are foam materials formed using supercritical gas, and the plate includes carbon fiber.

[0018] In yet another embodiment, the present disclosure provides footwear having an upper comprising densified wood and a sole structure coupled to the upper.

[0019] Other aspects, including features and advantages, of the footwear described herein will become apparent to those skilled in the art upon review of the drawings and detailed description herein, and therefore, all such aspects of the footwear are intended to be included in the detailed description and this summary. [Brief explanation of the drawings]

[0020] [Figure 1] FIG. 1 is a perspective view of footwear configured as a left shoe including an upper and sole structure as discussed herein. [Figure 2] FIG. 2 is a lateral side view of the shoe of FIG. 1. [Figure 3] FIG. 2 is a medial side view of the shoe of FIG. 1. [Figure 4] FIG. 2 is a top view of the shoe of FIG. 1. [Figure 5] 2 is a top view of the shoe of FIG. 1 with the upper removed and the user's skeletal foot structure superimposed thereon. [Figure 6] FIG. 2 is a bottom perspective view of the shoe of FIG. 1. [Figure 7] FIG. 2 is a bottom view of the shoe of FIG. 1. [Figure 8] 2 is an exploded view of the sole structure of FIG. 1, the sole structure including an outsole, a midsole body, a plate, a heel support, and a heel support collar. [Figure 9] FIG. 9 is a perspective view of the plate of FIG. 8. [Figure 10] FIG. 9 is a top view of the plate of FIG. 8. [Figure 11] FIG. 9 is a bottom view of the plate of FIG. 8. [Figure 12] FIG. 9 is an exterior side view of the plate of FIG. 8. [Figure 13] FIG. 9 is a top view of the plate of FIG. 8 with a user's skeletal foot structure superimposed thereon. [Figure 14] FIG. 9 is a perspective view of the midsole body of FIG. 8. [Figure 15] FIG. 9 is a bottom perspective view of the midsole body of FIG. 8. [Figure 16]FIG. 9 is a bottom view of the midsole body of FIG. 8. [Figure 17] FIG. 9 is a lateral side view of the midsole body of FIG. 8, with the internal structure shown in dashed lines. [Figure 18] FIG. 18 is a cross-sectional view of the sole structure of FIG. 7 taken along line 18-18. [Figure 19] FIG. 10 is an exploded top perspective view of another sole structure according to a second embodiment of the present disclosure. [Figure 20] FIG. 20 is an exploded bottom perspective view of the sole structure of FIG. 19. [Figure 21] FIG. 10 is an exploded bottom perspective view of yet another sole structure according to a third embodiment of the present disclosure. [Figure 22] FIG. 10 is an exploded bottom perspective view of yet another sole structure according to a fourth embodiment of the present disclosure. [Figure 23] FIG. 10 is an exploded top perspective view of another sole structure having an outsole, a lower midsole cushioning member, an upper midsole cushioning member, a heel support, and a plate according to a fifth embodiment of the present disclosure. [Figure 24] FIG. 13 is an exploded top perspective view of yet another sole structure having an outsole, a midsole, and a plate according to a sixth embodiment of the present disclosure. [Figure 25] FIG. 25 is a partial view of the sole structure of FIG. 24 with the plate in a first position relative to the midsole. [Figure 26] FIG. 25 is a partial view of the sole structure of FIG. 24 with the plate in a second position relative to the midsole. [Figure 27] FIG. 10 is a top view of another embodiment of a plate for a sole structure. [Figure 28] 28 is a lateral side view of a footwear having a sole structure with the plate of FIG. 27. FIG. [Figure 29] FIG. 29 is a top view of the sole of FIG. 28 with the internal components shown in dashed lines. [Figure 30] 30 is a cross-sectional view of the sole structure of FIG. 28 taken along line 30-30 of FIG. 29. [Figure 31] 31 is a cross-sectional view of the sole structure of FIG. 28 taken along line 31-31 of FIG. 29. [Figure 32] 32 is a cross-sectional view of the sole structure of FIG. 28 taken along line 32-32 of FIG. 29. [Figure 33] 33 is a cross-sectional view of the sole structure of FIG. 28 taken along line 33-33 of FIG. 29. [Figure 34] 34 is a cross-sectional view of the sole structure of FIG. 28 taken along line 34-34 of FIG. 29. [Figure 35] 35 is a cross-sectional view of the sole structure of FIG. 28 taken along line 35-35 of FIG. 29. [Figure 36] FIG. 1 is a perspective view of another sole structure for footwear. [Figure 37] FIG. 37 is an exploded perspective view of the sole structure of FIG. 36. [Figure 38] FIG. 37 is an exploded bottom perspective view of the sole structure of FIG. 36. [Figure 39] FIG. 10 is a bottom view of another sole structure for footwear. [Figure 40] FIG. 40 is a lateral side view of the sole structure of FIG. [Figure 41] FIG. 40 is a medial side view of the sole structure of FIG. [Figure 42] FIG. 40 is a front view of the sole structure of FIG. 39. [Figure 43] FIG. 40 is a rear view of the sole structure of FIG. 39. [Figure 44] FIG. 40 is a bottom medial perspective view of the sole structure of FIG. 39. [Figure 45] FIG. 40 is a bottom side perspective view of the sole structure of FIG. [Figure 46] 1 shows a general schematic diagram of one embodiment of the production of densified wood from natural wood. [Figure 47A] 1 shows an exploded view of a densified wood laminate. [Figure 47B] 1 shows a perspective view of a laminate of densified wood. [Figure 47C] 1 shows a perspective view of a densified wood laminate thin board. [Figure 48] 9 shows a perspective view of another embodiment of the plate of FIG. 8. [Figure 49] 1 is a front perspective view of a sporting goods structure configured as a shin guard, including a front and a rear surface. FIG. [Figure 50]FIG. 50 is a rear perspective view of the shin guard of FIG. 49. [Figure 51] 51 is a cross-sectional side view of the shin guard of FIG. 49 taken along line 51-51 of FIG. 50. [Figure 52] FIG. 10 is a front perspective view of another shin guard. [Figure 53] FIG. 53 is a rear perspective view of the shin guard of FIG. 52. [Figure 54] 54 is a cross-sectional side view of the shin guard of FIG. 52 taken along line 54-54 of FIG. 53. DETAILED DESCRIPTION OF THE INVENTION

[0021] Detailed Description of the Drawings The following description and accompanying drawings disclose various embodiments or configurations of shoes having upper and sole structures. While the embodiments are disclosed with respect to athletic shoes such as running shoes, tennis shoes, and basketball shoes, the concepts related to the shoe embodiments may be applied to a wide range of footwear and footwear styles, including, for example, cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and cleats, walking shoes, and track cleats. The shoe concepts may also be applied to footwear considered non-athletic, including dress shoes, sandals, loafers, slippers, and heels.

[0022] The term "about," as used herein, refers to variations in numerical quantities that may occur, for example, due to typical measuring and manufacturing procedures used for footwear or other products that may include embodiments disclosed herein, inadvertent errors in these procedures, differences in the manufacture, source, or purity of ingredients used to make a composition or mixture, or to take steps. Throughout this disclosure, the terms "about" and "approximately" refer to a range of values ​​of ±5% of the numerical value that the term precedes.

[0023] FIELD OF THE DISCLOSURE The present disclosure relates to footwear, or particular components of footwear, such as uppers, soles, or sole structures, that include or are at least partially formed from densified wood panels.

[0024] As used herein, "densified wood" or "densified wood panel" are used interchangeably and refer to engineered wood materials that have increased strength, toughness, and density compared to similarly unengineered wood panels. In some embodiments, densified wood panels have a density of about 1.1 g / cm 3 ~Approx. 1.9g / cm 3 In some embodiments, the densified wood panel has a density between about 1.5 g / cm 3 It has a density of

[0025] Suitable methods for forming densified wood from natural wood are known and described in the art, see, for example, WO 2019 / 055789, WO 2018 / 191181, and Song et al. (“Processing bulk natural wood into a high-performance structural material,” Nature, 2018, 554:224-228), each of which is incorporated herein by reference as if set forth in its entirety.

[0026] In some embodiments of the present disclosure, densified wood panels are made by a process that includes a first step of contacting bulk natural wood with a sodium-based chemical solution for a time and under conditions sufficient to remove lignin and hemicellulose from the natural wood and form delignified wood. The sodium-based chemical solution can be selected from the group consisting of NaOH, NaOH / Na2S, NaHSO3+SO2+H2O, NaHSCb, NaHSO3+Na2SO3, NaOH+Na2SO3, Na2SO3, NaOH+AQ, NaOH / Na2S+AQ, NaHSO3+SO2+H2O+AQ, NaOH+Na2SO3+AQ, NaHSO3+AQ, NaHSO3+Na2SO3+AQ, Na2SO3+AQ, NaOH+Na2S+Na2S, where n is an integer and AQ is an anthraquinone. n , Na2SO3 + NaOH + CH3OH + AQ, CH3OH, C2H5OH, C2H5OH + NaOH, C4H9OH, HCOOH, CH3COOH, CH3OH + HCOOH, C4H8O2, NH3.H2O, p-TsOH, H2O2, NaClO, NaClO2 + acetic acid, ClO2, and Cl2.

[0027] As used herein, "natural wood" refers to a composite of cellulose nanofibers embedded in a crosslinked matrix of lignin and hemicellulose found in nature and produced by plants. Natural wood for use in the delignification and densification processes described herein can be any type of softwood or hardwood, including, but not limited to, basswood, oak, poplar, ash, alder, aspen, balsawood, beech, birch, cherry, butternut, chestnut, cocobolo, elm, hickory, maple, oak, padauk, plum, walnut, willow, yellow poplar, balsawood, cedar, cypress, Douglas-fir, fir, hemlock, larch, pine, redwood, spruce, tamarack, juniper, and ginkgo. In some embodiments, the natural wood for use in densified wood is recycled or scrap wood.

[0028] Natural wood for use in the densified wood panels described herein may be selected based on its hardness. Methods for measuring hardness are known and described in the art, including, but not limited to, measuring the chipping resistance and abrasion resistance of a wood sample (e.g., Janka scale) or measuring the indentation hardness of a wood sample (e.g., Brinell scale). Table 1 below includes the Janka scale hardness of several natural wood samples that may be used in the densified wood panels described herein.

[0029] [Table 1]

[0030] As used herein, "delignified wood" refers to wood from which at least some or substantially all of the lignin has been removed. In some embodiments, delignified wood is wood from which at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, or at least 90% of the lignin has been removed. In some embodiments, densified wood is made from delignified wood from which at least 30% of the lignin has been removed. In some embodiments, densified wood is made from delignified wood from which at least 40% of the lignin has been removed. The lignin removal rate is measured relative to the lignin content in the natural wood prior to chemical delignification.

[0031] Removal of "substantially all lignin" refers to removing at least 90% of the lignin from the natural wood. In some embodiments, at least 90%, at least 95%, at least 98%, or at least 99% of the lignin is removed from the natural wood to form delignified wood. As used herein, "substantially free of lignin" refers to a wood product in which at least 98% of the lignin has been removed relative to the natural wood.

[0032] In some embodiments, the delignified wood also has a reduced hemicellulose content. In some embodiments, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 98%, or at least 99% of the hemicellulose has been removed from the natural wood during the formation of the delignified wood. As used herein, "substantially free of hemicellulose" refers to a wood product in which at least 98% of the hemicellulose has been removed relative to the natural wood.

[0033] Without wishing to be bound by any particular theory or methodology, removal of the lignin and hemicellulose components of natural wood results in delignified wood that is more porous and less stiff than natural wood due to its unique composition primarily consisting of cellulose nanofibrils with open lumens. Compression of delignified wood forms hydrogen bonds between the remaining cellulose nanofibers, thereby improving the mechanical properties of the densified wood.

[0034] Following delignification to form the delignified wood, the delignified wood is pressed to compress the cells of the delignified wood, thereby forming high-density wood. The delignified wood is pressed at a pressure of about 0.5 MPa to about 10 MPa. In some embodiments, the delignified wood is heated at about 100°F to about 250°F while being pressed. In some embodiments, the delignified wood is heated at about 150°F to about 220°F while being pressed.

[0035] In some embodiments, the thickness of the densified wood along the compression axis is reduced by at least 40%, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95% compared to the thickness of the natural wood along the same axis before delignification and densification.

[0036] In some embodiments, delignified wood is compressed to form transparent wood rather than forming densified wood. As used herein, "transparent wood" refers to a composite material composed of polymeric materials and preserved, naturally aligned nanoscale cellulose fibers. As described above with respect to the delignification and formation of densified wood, the natural cellulose fibers remain intact in their naturally occurring orientation after delignification. When a polymeric material is introduced into the delignified wood product, the gaps and spaces left by the delignification process are replaced with a transparent polymeric material, preserving the naturally occurring cellulose fiber orientation and structure to form a transparent wood material. Suitable polymeric materials include, but are not limited to, thermosetting polymers, thermoplastic polymers, cellulosic polymers, epoxy resins, polymeric nanoglues, polyvinylpyrrolidone (PVP), poly(methyl methacrylate) (PMMA), poly(vinyl alcohol) (PVA), and polydimethylsiloxane (PDMS). Suitable methods for forming transparent wood from natural wood are known and described in the art. See, for example, WO 2017 / 136714 and Zhu et al. (“Highly anisotropic, highly transparent wood composites,” Advanced Materials, 2016, 28(26):5181-5187), each of which is incorporated by reference herein as if set forth in its entirety. It is contemplated that transparent wood may be used in addition to or in place of densified wood in any of the embodiments described herein.

[0037] In some embodiments, viscoelastic thermal pressing (VTC) is used to densify natural wood without delignification. Methods for VTC treatment of natural wood to form densified wood are known and described in the art. See, for example, Kutner et al. ("The mechanical properties of densified VTC wood relative for structural composites," Holz als Roh- und Werkstoff, Volume 66, pages 439-446, 2008), U.S. Patent No. 7,404,422, and U.S. Patent No. 5,415,943, each of which is incorporated herein by reference in its entirety.

[0038] During compression of delignified wood or VTC of natural wood, the wood can be shaped into a desired form. For example, wood can be compressed and heated to form a densified wood panel curved into the shape of plate 170, as shown in FIG. 9 . In another example, wood can be compressed and heated to form a panel with a series of protrusions in the shape of sole plate 1002, as shown in FIG. 39 . Densified wood panels suitable for use in footwear of the present disclosure may take any shape or configuration suitable for incorporation into footwear described herein. In some embodiments, the densified wood panel is shaped to include ridges, grooves, ribs, or other structures to provide support and reinforcement when incorporated into footwear. The shapes and configurations of densified wood panels are not limited to those shapes and configurations shown herein.

[0039] In some embodiments, the densified wood panel is a laminate incorporating two or more layers of delignified or natural wood. In some embodiments, the densified wood panel laminate is made by placing at least two layers of delignified or natural wood and compressing the at least two layers together. In some embodiments, the densified wood panel laminate is made by bonding the two or more layers of densified wood after the densified wood panel laminate has been compressed. In some embodiments, the densified wood panel laminate comprises at least two, at least three, at least four, at least five, or at least six layers.

[0040] As shown in Figures 47A-47C, the layers 1102a, 1102b in a densified wood laminate 1100 may be arranged parallel, with the cellulose microfiber lumens 1104a, 1104b oriented perpendicular to the adjacent layers 1102a, 1102b. In Figure 47A, a first layer 1102a has cellulose microfiber lumens 1104a oriented in a first direction that is perpendicular to the cellulose microfiber lumens 1104b in the second layer 1102b. The first and second layers 1102a, 1102b may be combined to form a laminate unit 1106, and the laminate unit may be joined to form the densified wood laminate 1100. Alternatively, the layers in a densified wood panel laminate may be arranged such that the cellulose microfiber lumens of one layer are parallel to the cellulose microfiber lumens of an adjacent layer (not shown). In some embodiments, one or more layers of the densified wood laminate are replaced with a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, a thermoplastic olefin, or one or more fibers, such as carbon fiber, aramid fiber, boron fiber, glass fiber, natural fiber, and polymer fiber, or a combination thereof, to form a composite.

[0041] In some embodiments, delignified wood is pretreated prior to or simultaneously with pressing or VTC processing. Treatment of delignified, natural, or densified wood can impart additional beneficial properties, such as increased hydrophobicity, weather resistance, corrosion resistance (e.g., saltwater resistance), and flame resistance. In some embodiments, the delignified or densified wood is treated with an epoxy resin, silicone oil, polyurethane, paraffin emulsion, acetic anhydride, octadecyltrichlorosilane (OTS), 1H,1H,2H,2H-perfluorodecyltriethoxysilane, fluoroesin, polydimethylsiloxane (PDMS), methacryloxymethyltrimethylsilane (MSi), polyhedral oligomeric silsesquioxane (POSS), methylsiliconate silicate (PMS), dodecyl(trimethoxy)silane (DTMS), hexamethyldisiloxane, dimethyldiethoxysilane, tetraethoxysilane, methyltrimethoxysilane, methyltriethoxysilane, trimethylchlorosilane, phenyltrimethoxysilane, phenyltriethoxysilane, propyltrimethoxysilane, polymethylmethacrylate, polydiallyldimethylammonium chloride (polyDADMAC), 3-(trimethoxysilyl)propyl The delignified or densified wood may be pretreated or treated with chemicals that provide improved hydrophobicity, including, but not limited to, polyvinylidene fluoride (MPS), hydrophobic stearic acid, amphiphilic fluorinated triblock azide copolymer, polyvinylidene fluoride and fluorinated silanes, n-dodecyltrimethoxysilane, and sodium lauryl sulfate. In some embodiments, the delignified or densified wood may be pretreated or treated with chemicals to improve weathering and corrosion resistance, including cupramate (CDDC), quaternary ammoniacal copper (ACQ), zinc chromate copper arsenate (CCA), ammoniacal copper arsenate (ACZA), copper naphthenate, copper acid chromate, copper citrate, azole copper, copper 8-hydroxyquinolinate, pentachlorophenol, zinc naphthenate, copper naphthenate, creosote, titanium dioxide, propiconazole, tebuconazole, cyproconazole, boric acid, borax, organic iodides (IPBC), and Na 2 B 8 O13 4H 2 O In some embodiments, the delignified or densified wood may be pre-treated or treated with chemicals to provide a particular color, shade, or hue, such as, but not limited to, a paint, stain, or varnish.

[0042] In some embodiments, when incorporated into footwear, the densified wood panel has a thickness of between about 0.5 mm and about 5 mm. In some embodiments, the thickness of the densified wood panel is about 0.5 mm to about 3.0 mm, or about 0.75 mm to about 3 mm, or about 0.5 mm to about 2.0 mm, or about 0.7 mm to about 1.0 mm. In some embodiments, the thickness of the densified wood panel is about 1 mm. The densified wood when incorporated into footwear may have a uniform or non-uniform thickness.

[0043] The densified wood panel may be incorporated into a portion of, or may form the entirety of, an upper (e.g., an outer surface, a tongue, eyelets, a straw board, etc.) or a sole portion (e.g., an outsole, a plate, a cleat plate, a midsole, etc.). Various embodiments of uppers including outer surfaces, tongues, eyelets, and straw boards, and sole portions including plates, outsoles, cleat plates, and midsoles, as well as footwear suitable for use with the densified wood panels or portions thereof described herein are shown in FIGS. 1-45. The embodiments shown in FIGS. 1-45 are not intended to limit the scope of the present disclosure, and one skilled in the art will recognize that densified wood panels, as described herein, may be incorporated into various locations on and within footwear.

[0044] In addition to or as an alternative to densified wood, the upper may include knitted elements, woven fabrics, nonwoven fabrics, leather, mesh, suede, densified wood panels, or a combination of one or more of the aforementioned materials. Knitted elements may be made by knitting yarns, woven fabrics by weaving yarns, and nonwoven fabrics by manufacturing a monolithic nonwoven web. Knitted fabrics include fabrics formed by warp knitting, weft knitting, flat knitting, circular knitting, or other suitable knitting operations. Knitted fabrics may have, for example, a plain knit, mesh knit, or rib knit structure. Woven fabrics include fabrics formed by any of a number of weaving forms, such as, but not limited to, plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weave, or double cloth weave. Nonwoven fabrics include, for example, fabrics made by airlaid or spunlaid processes. The upper may comprise a variety of materials, such as first, second, or third yarns, which may have different properties or visual characteristics.

[0045] 1-7 illustrate an exemplary embodiment of footwear configured as a shoe 100 including an upper 102 and a sole structure 104. As discussed further herein, the upper 102 is attached to the sole structure 104 and, together with the sole structure 104, defines an interior cavity 106 (see FIGS. 1 and 4 ) into which a user's foot may be inserted. For reference, the footwear 100 includes a forefoot region 108, a midfoot region 110, and a heel region 112 (see FIGS. 4 and 5 ). The forefoot region 108 generally corresponds to the portion of the footwear 100 that encompasses the toes, ball of the foot, and the joints connecting the metatarsals to the toes or phalanges. The midfoot region 110 is proximate to the forefoot region 108 and generally corresponds to the portion of the footwear 100 that encompasses the arch of the foot, including the heel region 112. bridge Heel region 112 is closely adjacent to midfoot region 110 and generally corresponds to the portion of footwear 100 that wraps around the rear of the foot, including the heel or calcaneus, ankle, or Achilles tendon.

[0046] Although only a single shoe 100 is depicted, i.e., a shoe worn on a user's left foot, it should be understood that the concepts disclosed herein are applicable to a pair of shoes (not shown), including a left shoe and a right shoe, which may be sized and shaped to accommodate a user's left and right feet, respectively. However, for ease of disclosure, a single shoe is referenced to describe aspects of the present disclosure, but the following disclosure with reference to footwear 100 is applicable to both the left and right shoes. However, in some embodiments, there may be differences between the left and right shoes other than the left / right configuration. Furthermore, in some embodiments, the left shoe may include one or more additional elements that the right shoe does not include, or vice versa.

[0047] Continuing with reference to FIGS. 1-7 , upper 102 is shown positioned above and joined to sole structure 104. Upper 102 can be formed from multiple elements, such as textile, polymer foam, polymer sheet, leather, synthetic leather, or densified wood, conventionally joined by glue or stitching at seams. In some embodiments, upper 102 of footwear 100 is formed from a knit structure or knitted elements. In various embodiments, knitted elements may incorporate different types of yarns, which may provide different properties to the upper. For example, the upper mesh layer may be warp knit, while the mesh backing layer may comprise a circular knit. In some embodiments, upper 102 of footwear 100 comprises one or more densified wood panels.

[0048] In some embodiments, the various layers of the upper 102 are heat-pressed together to bond the various layers of the upper 102. For example, the layers comprising the upper 102 can all be heat-pressed together at once and at a single temperature. The upper 102 may further be attached to a strobel board 114 (see FIG. 4 ) by a strobel stitch (not shown). Dowel pins (not shown) may be used to align the various holes (not shown) in the upper 102 during manufacture of the upper 102. In some embodiments, the various layers of the upper 102 may be waterproof or semi-waterproof and may include multiple layers of mesh or other materials. The materials comprising the upper 102 may include an inner mesh layer, a thermoplastic polyurethane (TPU) film, and an outer mesh layer. In some embodiments, a TPU skin may be applied along the other surface of the upper.

[0049] In some embodiments, one or more layers of upper 102 comprise densified wood. In some embodiments, part or all of exterior surface 130 is formed from densified wood. In some embodiments, part or all of strobel board 114 is formed from densified wood.

[0050] With respect to the material or materials comprising the upper 102, the specific properties that a particular type of yarn will impart to a region of the knitted element may depend, at least in part, on the materials forming the various filaments and fibers of the yarn. For example, cotton may provide a knitted material with a soft effect, biodegradability, or a natural aesthetic. Elastane and oriented polyester may each provide a knitted element with desired elasticity and recovery. Rayon may provide a high-shine and moisture-wicking material, wool may provide a material with increased moisture-wicking properties, nylon may be a durable material that is abrasion-resistant, and polyester may provide a hydrophobic and durable material.

[0051] Other aspects of the knitted members may also be varied to affect the properties of the knitted members and provide desired attributes. For example, the yarns forming the knitted members may include monofilament yarns or multifilament yarns, or the yarns may each include filaments formed from two or more different materials. In addition, the knitted members may be formed using specific knitting processes to impart specific properties to regions of the knitted members. Thus, both the materials forming the yarns and other aspects of the yarns may be selected to impart different properties to specific regions of the upper 102.

[0052] In some embodiments, the elasticity of a knit structure may be measured based on comparing the width or length of the knit structure in a first, unstretched state to the width or length of the knit structure in a second, stretched state after a lateral force is applied to the knit structure.

[0053] In some embodiments, the upper 102 may include additional structural elements, or additional structural elements may surround or be coupled to the upper 102. For example, a heel cup may be provided at the heel end 116 in the heel region 112 of the shoe 100 to provide additional support for the user's heel. In some embodiments, the heel cup may be formed partially or entirely from densified wood. In some examples, other elements, such as plastic materials, densified wood materials, logos, trademarks, etc., may also be applied and secured to the exterior surface using adhesives or a thermoforming process. In some embodiments, uppers associated with different stitch types or thread types may vary, e.g., the stitch type, thread type, or properties associated with the different stitch types or thread types, such as elasticity, aesthetic appearance, thickness, breathability, or abrasion resistance.

[0054] 1-7 , footwear 100 also includes a fastening system 118 including laces 120 and a plurality of eyelets 122. In this embodiment, laces 120 extend through a plurality of eyelets 122. In some embodiments, the eyelets are formed of densified wood. In some embodiments, fastening system 118 may include an elastic lace. Fastening system 118 may allow a user to modify the dimensions of upper 102, for example, to tighten or loosen a portion of upper 102 around the foot as desired by the wearer. Fastening system 118 may also include a band (not shown) running along the center of upper 118 and including one or more loops to guide laces 120. In other embodiments, fastening system 118 may be a hook-and-loop fastening system such as Velcro®. For example, in some embodiments, fastening system 118 may include one or more hook-and-loop straps. In further embodiments, fastening system 118 may be another laceless fastening system known in the art. In yet other embodiments, fastening system 118 may include a different manual fastening system, a rotary closure, or an automatic fastening system, such as those described in U.S. Patent Application No. 15 / 780,368, filed May 31, 2018, and U.S. Patent Application No. 16 / 392,470, filed April 23, 2019, both of which are incorporated by reference herein in their entireties. In some embodiments, part or all of eyelet 122 may be formed from densified wood.

[0055] 2 and 3, footwear 100 also defines a lateral side 124 and a medial side 126, with lateral side 124 shown in FIG. 2 and medial side 126 shown in FIG. 3. Laces 120 extend from lateral side 124 to medial side 126. lateral side 124 corresponds to the portion of footwear 100 that faces outward when the shoe is worn by a user, while medial side 126 corresponds to the portion of footwear 100 that faces inward. Thus, the left shoe and the right shoe have opposing lateral sides and medial sides, with the medial sides being closest to each other when the user is wearing the shoes, while the lateral sides are defined as the sides that are furthest from each other while the shoes are being worn. As discussed in more detail below, medial side 126 and lateral side 124 are adjacent to each other at opposite distal ends of footwear 100.

[0056] 4 and 5, upper 102 extends along a lateral side 124 and a medial side 126 and across a forefoot region 108, a midfoot region 110, and a heel region 112 to accommodate and encase a user's foot. When fully assembled, upper 102 also includes an inner surface 128 and an outer surface 130. Inner surface 126 faces inward and generally defines interior cavity 106, while outer surface 130 of upper 102 faces outward and generally defines the periphery or boundary of upper 102. Inner surface 128 and outer surface 130 may comprise portions of the upper layer disclosed above. Upper 102 also includes an opening 132 located at least partially in heel region 112 of footwear 100 that provides access to interior cavity 106 (see, for example, FIG. 4 ) and through which the foot can be inserted and removed. In some embodiments, the upper 102 may also include an instep region 134 that extends from the opening 132 in the heel region 112, across an area corresponding to the instep of the foot, to an area adjacent to the forefoot region 108. The instep region 134 may comprise an area similar to the area in which the tongue 136 of this embodiment is located. In some embodiments, the upper 102 does not include the tongue 136, i.e., the upper 102 is tongueless. In some embodiments, part or all of the tongue 136 is formed from densified wood.

[0057] 5 , the medial side 126 and the lateral side 124 are adjacent to one another along a longitudinal central plane or axis 150 of the footwear 100. As discussed further herein, the longitudinal central plane or axis 150 may define a central, intermediate axis between the medial side 126 and the lateral side 128 of the footwear 100. In other words, the longitudinal plane or axis 150 may extend between the heel end 116 of the footwear 100 and the toe end 152 of the footwear 100, or may continuously define the middle of the insole, sole structure 104, or upper 102 of the footwear 100; i.e., the longitudinal plane or axis 150 may be a linear axis extending through the heel end 116 of the heel region 112 to the toe end 152 of the forefoot region 108.

[0058] Forefoot region 108, midfoot region 110, heel region 112, medial side 126, and lateral side 124 are intended to define boundaries or regions of footwear 100. As such, forefoot region 108, midfoot region 110, heel region 112, medial side 126, and lateral side 124 generally characterize sections of footwear 100. Particular embodiments of the present disclosure may refer to portions or elements coexisting in one or more of forefoot region 108, midfoot region 110, heel region 112, medial side 126, or lateral side 124. Additionally, both upper 102 and sole structure 104 may be characterized as having portions within forefoot region 108, midfoot region 110, heel region 112, or along medial side 126 or lateral side 124. Thus, the upper 102 and sole structure 104, or individual portions of the upper 102 and sole structure 104, may include portions thereof located within the forefoot region 108, midfoot region 110, heel region 112, or along the medial side 126 or lateral side 124.

[0059] 5, the toe region 108, midfoot region 110, heel region 112, medial side 126, and lateral side 124 are shown in detail. The toe region 108 extends from a toe tip 152 to a widest portion 154 of the footwear 100. The widest portion 154 is defined or measured along a first line 156 that is perpendicular to a longitudinal axis 150 that extends from a distal portion of the toe tip 152 to a distal portion of the heel end 116 opposite the toe tip 152. The midfoot region 110 extends from the widest portion 154 to a narrowest portion 158 of the footwear 100. The narrowest portion 158 of the footwear 100 is defined as the narrowest portion of the footwear 100 measured along a second line 160 that is perpendicular to the longitudinal axis 150. The heel region 112 is the narrowest portion of the footwear 100. 158 to the heel end 116.

[0060] In view of the foregoing description, it should be understood that numerous variations may be apparent to those skilled in the art, and that individual components thereof may be incorporated into numerous articles of footwear. Accordingly, aspects of footwear 100 and its components may be described with reference to general areas or portions of footwear 100, understanding the boundaries of forefoot region 108, midfoot region 110, heel region 112, medial side 126, or lateral side 124, as described herein. However, aspects of footwear 100 and its individual components may also be described with reference to precise areas or portions of footwear 100, and the appended claims herein may incorporate limitations related to these boundaries of forefoot region 108, midfoot region 110, heel region 112, medial side 126, or lateral side 124, as discussed herein.

[0061] 5 , the medial side 126 begins at the distal toe tip 152 and curves outward along the forefoot region 108 toward the midfoot region 110. At a first line 156, the medial side 126 curves inward toward the central longitudinal axis 150. The medial side 126 extends from the first line 156, i.e., widest portion 154, to a second line 160, i.e., narrowest portion 158, where it crosses the first line 156 and enters the midfoot region 110. After reaching the second line 160, the medial side 126 curves outward away from the central longitudinal axis 150, at which point the medial side 126 extends into the heel region 112, i.e., beyond the second line 160. The medial side 126 then curves outward and then inward toward the heel end 116, terminating at the point where the medial side 126 intersects the central longitudinal axis 150.

[0062] Continuing with reference to FIG. 5 , the lateral side 124 also begins at the distal toe tip 152 and curves outward along the forefoot region 108 toward the midfoot region 110. At the point where the lateral side 124 curves inward toward the central longitudinal axis 150, the lateral side 124 reaches a first line 156. The lateral side 124 extends from the first line 156, i.e., widest portion 154, to a second line 160, i.e., narrowest portion 158, and crosses the first line 156 to enter the midfoot region 110. After reaching the second line 160, the lateral side 124 extends into the heel region 112; i.e., at the point beyond the second line 160, the lateral side 124 curves outward away from the central longitudinal axis 150. The lateral side 124 then curves outward and then inward toward the heel end 116, terminating at the point where the lateral side 124 meets the central longitudinal axis 150.

[0063] 2 and 3 , sole structure 104 includes an outsole or outsole region 162, a midsole or midsole region 164, and an insole or insole region (not shown). In some embodiments, sole structure 104 includes an insole, but in the illustrated embodiment, the insole is a separate element inserted into the foot cavity above strobel board 114. Outsole 162, midsole 164, and insole, or any component thereof, may include portions within forefoot region 108, midfoot region 110, or heel region 112. Furthermore, outsole 162, midsole 164, and insole, or any component thereof, may include portions on lateral side 124 or medial side 126. Outsole 162, midsole 164, and any other portions of sole structure 104 may be attached to one another via adhesive (not shown). Upper 102 is further attached to the sole structure via gluing or stitching.

[0064] In some embodiments, footwear 100 includes an insole that includes densified wood. Part or all of the insole may be made from densified wood. In some embodiments, the densified wood of the insole incorporates aluminum and has antibacterial or anti-odor properties.

[0065] In some examples, outsole 162 may be defined as the portion of sole structure 104 that at least partially contacts an exterior surface, such as the ground, when footwear 100 is worn. Insole 164 may be defined as the portion of sole structure 104 that at least partially contacts a user's foot when footwear 100 is worn. Finally, midsole 164 may be defined as at least a portion of sole structure 104 that extends from the outsole toward upper 102 or otherwise extends between and connects outsole 162 and an insole region.

[0066] With particular reference to FIG. 8 , which is an exploded view of sole structure 104 of footwear 100, sole structure 104 may include outsole 162, plate 170, heel cushioning member 172, heel support collar 174, and midsole cushioning member 176. In this embodiment, midsole cushioning member 176 includes opening 178 (see FIGS. 14 and 15 ) through which rear segment 179 of plate 170 (see FIGS. 9-13 ) can be inserted, as discussed further herein. While outsole 162, plate 170, heel cushioning member 172, heel collar 174, and midsole cushioning member 176 are separate components in this embodiment, in alternative embodiments, these components, or portions thereof, may be integrated with other components. For example, in some embodiments, heel cushioning member 172 and heel support collar 174 may be integrated or a single piece.

[0067] As shown in Figures 8 and 18, which are cross-sectional views of sole structure 104, outsole 162 may define a bottom edge or surface of sole structure 104 across heel region 112, midsole region 110, and forefoot region 108. Additionally, as discussed previously herein, outsole 162 may be the ground-engaging portion of sole structure 104, as opposed to an insole. Outsole 162 may be formed from one or more materials to impart durability, abrasion resistance, wear resistance, or traction to sole structure 104. In some embodiments, outsole 162 may be formed from rubber, for example.

[0068] In this embodiment, the sole structure 104 may also include a heel cushioning member 172, which may be disposed adjacent to and on the outsole 162 in the heel region 112 and partially in the midfoot region 110. In other words, the heel cushioning member 172 may be adjacent to the outsole 162 and may extend from the heel end 116 of the sole structure 104, through the heel region 112, and partially through the midfoot region 110. The heel cushioning member 172 may also include a cutout 180 defined by a lateral prong 182 and a medial prong 184. The heel cushioning member 172 may be constructed from ethylene vinyl acetate (EVA), copolymers thereof, or similar types of materials. For example, in some embodiments, the heel cushioning member 172 is made of an EVA-Solid-Sponge (“ESS”) material, EVA foam (e.g., PUMA® ProFoam Lite TM , IGNITE foam), polyurethane, polyether, olefin block copolymer, thermoplastic material (e.g., thermoplastic polyurethane, thermoplastic elastomer, thermoplastic polyolefin, etc.), or supercritical foam. Heel cushion member 172 may be a single polymer material or a blend of materials such as EVA copolymer, thermoplastic polyurethane, polyether block amide (PEBA) copolymer, and / or olefin block copolymer.

[0069] In embodiments in which heel cushioning member 172 is formed from a supercritical foaming process, the supercritical foam may include microporous or particle foams such as TPU, EVA, PEBAX®, or mixtures thereof, manufactured using a process carried out in an autoclave, injection molding equipment, or any sufficiently heated / pressurized vessel capable of processing the mixture of a supercritical fluid (e.g., CO, N, or mixtures thereof) with a material (e.g., TPU, EVA, polyolefin elastomer, or mixtures thereof), preferably in a molten state. During an exemplary process, a solution of supercritical fluid and molten material is pumped into a pressurized vessel, after which the pressure in the vessel is released, causing the molecules of the supercritical fluid to rapidly turn into a gas, forming small pockets within the material and expanding the material into a foam, which may be used as heel cushioning member 172. In further embodiments, heel cushion member 172 may be formed using alternative methods known in the art, including the use of an expansion press, an injection molding machine, a pellet expansion method, a cold foaming method, a compression molding method, a die-cutting method, or any combination thereof. For example, heel cushion member 172 may be formed using a process involving an initial foaming step in which a supercritical gas is used to foam a material that is then compression molded or die-cut into a particular shape. However, in certain embodiments, heel cushion member 172 is provided to reduce stress or increase the strength of a portion of sole structure 104, such as heel region 112. As such, in these embodiments, heel cushion member 172 has a greater stiffness (e.g., tensile strength or flexural strength) than midsole cushion member 176.

[0070] The heel cushion member 172 has a resistance of approximately 0.05 g / cm (g / cm 3 ) ~ approx. 0.30g / cm 3 , or approximately 0.10 g / cm 3 ~Approx. 0.20g / cm 3In yet another embodiment, the heel cushion member 172 may have a hardness between about 10 Shore A and about 50 Shore A. In yet another embodiment, the heel cushion member 172 may be an air bladder encasing a plurality of beads, such as a plurality of spherical or elliptical beads or pellets formed from thermoplastic polyurethane, thermoplastic elastomer, or supercritical foam. Furthermore, the beads or pellets may be uniformly shaped, non-uniformly shaped, or a combination of uniform and non-uniform shapes, e.g., a plurality of spherical and elliptical beads or pellets. Furthermore, it is contemplated that the beads or pellets may have any geometric shape. For example, the heel cushion member 172 may define an interior void (not shown) that receives a pressurized fluid or a plurality of elliptical or spherical beads, such as the hollow space filled with several plastic bodies described in International Publication No. WO 2017 / 097315, filed December 7, 2015, the entire contents of which are incorporated herein by reference.

[0071] 8 and 18 , the heel support collar 174 may be adjacent to and disposed above the heel cushioning member 172, or adjacent to and disposed below the midsole cushioning member 176. In certain embodiments, the heel support collar 174 may have a shape similar to the perimeter wall 186 of the heel cushioning member 172. For example, in this particular embodiment, the heel support collar 174 is generally U-shaped or horseshoe-shaped, similar to the perimeter wall 186 of the heel cushioning member 172. Furthermore, as best shown in FIG. 18 , the outer edge 188 of the heel support collar 174 may extend a distance rearward beyond the rear end 190 of the heel cushioning member 172 and the rear end 192 of the midsole cushioning member 176. The heel support collar 174 may be formed from a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, or a thermoplastic olefin. Additionally, in certain embodiments, heel support collar 174 may have a hardness of between about 10 Shore A and about 90 Shore A. In some embodiments, heel support collar 174 may have a hardness or stiffness value that is greater than the hardness or stiffness value of heel cushioning member 176.

[0072] Sole structure 104 also typically includes a midsole cushioning member 176, which may be adjacent to and overlying outsole 162 in the forefoot region 108 and adjacent to and overlying heel cushioning member 172 in the heel region 112 of footwear 100. Sole structure 104 may also include recesses 194, 196 (see FIGS. 15 and 16 ) that communicate with, are embedded in, or are enclosed within at least a portion of plate 170 and heel cushioning member 172, as discussed further herein. Additionally, as described further herein, midsole cushioning member 176 includes an opening 178 through which a portion of plate 170 can extend, such that a portion of plate 170, e.g., rear segment 179, is vertically above midsole cushioning member 176 in heel region 112 (see FIG. 18 ), and a portion of plate 170, e.g., arch segment 200 and / or toe segment 202 (see FIGS. 10 and 12 ), is vertically below midsole cushioning member 176 in midfoot region 110 and / or forefoot region 108 (see FIG. 18 ) of footwear 100. In this embodiment, midsole cushioning member 176 may also include a recess 196 (see FIG. 14 ) in heel region 112 that cooperates with and defines the shape and size of rear segment 179 of plate 170. For example, in this particular embodiment, the top surface 206 , which may be the Strobel board 114 , may include a recess 196 .

[0073] 14-16 , midsole cushioning member 176 may include an upper surface 206, which may be strobel board 114, and a recess 196 in heel region 112 similar to rear segment 179 of plate 170. Midsole cushioning member 176 may further include a bottom surface 207 having recesses 194 in forefoot region 108 and midfoot region 110 of footwear 100 similar to toe segment 202 and arch segment 200 of plate 170. Further, opening 178 is adjacent to front end 208 of recess 196, i.e., the end of recess 196 closest to toe tip 152 of footwear 100, and adjacent to rear end 209 of recess 194, i.e., the end of recess 194 closest to heel end 116 of footwear 100.

[0074] In some embodiments, the sidewall may partially surround a portion of the periphery of the midsole cushioning member 176 to define a cavity that helps support and retain the foot. For example, in this particular embodiment, the midsole cushioning member 176 may include a sidewall that forms a rim around the heel region 112 and at least a portion of the midfoot region 110 of the footwear 100 that acts to cradle and support the foot during use of the footwear 100.

[0075] The midsole cushioning member 176 may be constructed from EVA, its copolymers, or similar types of materials. For example, in some embodiments, the midsole cushioning member 176 may be constructed from an ESS material, EVA foam (e.g., PUMA® ProFoam Lite TM, IGNITE foam), polyurethane, polyether, olefin block copolymer, thermoplastic material (e.g., thermoplastic polyurethane, thermoplastic elastomer, thermoplastic polyolefin, etc.), or supercritical foam. Like heel cushioning member 172, midsole cushioning member 176 may be a single polymer material or a blend of materials such as EVA copolymer, thermoplastic polyurethane, polyester block amide (PEBA) copolymer, and / or olefin block copolymer. Additionally, midsole cushioning member 176 may be formed from a supercritical foaming process in which a supercritical gas, such as CO2, N2, or a mixture thereof, is used to foam a material, such as EVA, TPU, TPE, or a mixture thereof. In such an embodiment, midsole cushioning member 176 may be manufactured using a process carried out in an autoclave, an injection molding apparatus, or any sufficiently heated / pressurized vessel capable of processing the mixture of a supercritical liquid (e.g., CO2, N2, or a mixture thereof) with a material (e.g., TPU, EVA, polyolefin elastomer, or a mixture thereof), preferably in a molten state. For example, in an exemplary process, a solution of supercritical fluid is mixed with molten material. This mixture is pumped or injected into a pressurized container, and then the pressure in the container is released, causing the supercritical fluid molecules to rapidly turn into a gas, forming small pockets within the material and expanding the material into a foam, which may be used as midsole cushioning member 176. In further embodiments, midsole cushioning member 176 may be formed using alternative methods known in the art, including the use of an expansion press, an injection molding machine, a pellet expansion method, a cold foaming method, a compression molding technique, a die-cutting method, or any combination thereof. In certain embodiments, midsole cushioning member 176 may be formed using a process that includes an initial foaming step (during which a supercritical gas is used to foam the material) and a second step (during which the foamed material is compression molded or die-cut into a particular shape).For example, the midsole cushioning member 176 may be formed using a process that includes an initial foaming step using a supercritical fluid to foam the material, and then a second step of compression molding the foamed material to form concave surfaces 194, 196 on the top and bottom surfaces 206, 207, respectively, of the midsole cushioning member 176.

[0076] In certain embodiments, midsole cushioning member 176 is provided to provide sufficient cushioning to sole structure 104. Midsole cushioning member 176 has a tensile strength of approximately 0.05 g / cm 3 ~Approx. 0.20g / cm 3 , or approximately 0.10 g / cm 3 ~Approx. 0.20g / cm 3 In yet another embodiment, midsole cushioning member 176 may have a density between about 10 Shore A and about 50 Shore A. In yet another embodiment, midsole cushioning member 176 may be an air bladder enclosing a plurality of beads, such as a plurality of spherical or elliptical beads or pellets formed from thermoplastic polyurethane, thermoplastic elastomer, or supercritical foam. For example, midsole cushioning member 176 may define an interior void (not shown) that receives a pressurized fluid or a plurality of beads, such as the hollow space filled with a plurality of plastic bodies described in International Publication No. WO 2017 / 097315, filed December 7, 2015, and discussed above.

[0077] 8 and 18 , sole structure 104 may include plate 170, or multiple plates, disposed therein. In certain embodiments, plate 170 may be disposed adjacent to and between outsole 162 and midsole cushioning member 176 in the forefoot region 108 of footwear 100, such that plate 170 is vertically below midsole cushioning member 176 in the forefoot region 108 and / or vertically below midsole cushioning member 176 in the midfoot region 110 of footwear 100. Further, as mentioned above, midsole cushioning member 176 includes recess 194 into which plate 170 may fit or be secured such that midsole cushioning member 176 at least partially encases plate 170. Plate 170 also extends through opening 178, and more specifically, a rear segment 179 of plate 170 extends through opening 178. Thus, in this embodiment, at least a portion of rear segment 179 is located above midsole cushioning member 176. Additionally, recess 196 of midsole cushioning member 176 may partially encase rear segment 179 of plate 170. In this particular embodiment, recess 196 of midsole cushioning member 176 completely surrounds and encases rear segment 179 such that upper surface 274 of plate 170 is flush with upper surface 206 of midsole cushioning member 176 (see FIG. 18 ).

[0078] 9-13 illustrate a footwear plate or plate 170 that may be incorporated into footwear 100. FIG. 9 provides a top perspective view of plate 170, FIG. 10 provides a top view of plate 170, FIG. 11 provides a bottom view of plate 170, FIG. 12 provides a side view of plate 170, and FIG. 13 provides another top view of plate 170 with the skeletal structure of a left foot superimposed thereon.

[0079] Plate 170 may be defined by a rear segment 179, an arch segment 200, and a toe segment 202. Referring to FIGS. 10 and 18, rear segment 179 may extend through at least the heel region 112 of footwear 100 when assembled therein and may correspond to a portion of plate 170 positioned near the rear of the foot, including the heel or calcaneus, ankle, or Achilles tendon. Arch segment 200 of plate 170 is closely adjacent to rear segment 179 and corresponds to a portion of plate 170 positioned near the midfoot region 110 of footwear 100 that encases the arch of the foot and the toe region 112 of the foot. bridge The toe segment 202 of the plate 170 corresponds to the portion of the plate 170 located near the forefoot region 108 of the footwear 100 that is closely adjacent to the arched segment 200 and that encompasses the portion of the foot including the toes, the ball of the foot, and the joints connecting the metatarsals with the toes or phalanges (i.e., the metatarsophalangeal joints).

[0080] 9-13, the toe segment 202 of the plate 170 may also include a cleft 210 that bisects the toe segment 202 into a first toe segment portion 212 on the outside of the plate 170 and a second toe segment portion 214 on the inside of the plate 170. In this embodiment, the cleft 210 may be defined by an inner wall 216 of the first toe segment portion 212 and an inner wall 218 of the second toe segment portion 212 and may be generally curved or parabolic. As shown in FIG. 13, the first toe segment portion 212 may support the fourth and fifth toes or phalanges, and the second toe segment portion 214 may support the first and second toes or phalanges, as discussed further herein. In alternative embodiments, the sizes of the first toe segment portion 212, the second toe segment portion 214, and the cleft 210 may vary, such that the first toe segment portion 212 and / or the second toe segment portion 214 may individually support any one of the toes or phalanges, as described later herein.

[0081] As best shown in FIG. 10 , the plate 170 may also be defined by a first end 220 that is the distal end of the second toe segment portion 214 and a second end 222 that is the distal end of the rear segment 179. In this embodiment, the plate 170 may also include a third end 224 that is the distal end of the first toe segment portion 212. In these embodiments, the length L1 of the plate 170 may be defined by the distance between the first end 220 and the second end 222 and may be less than or equal to the length of the midsole cushioning member 176. The plate 170 may also include a lateral side 226 and a medial side 228 that extend between the first end 220 and the second end 222. The distance between the lateral side 226 and the medial side 228 may also vary between the first end 220 and the second end 222 of the plate 170 and may define a width, e.g., width W1, of the plate 170.

[0082] 10 , medial side 228 begins at first end 220 and curves outward along toe segment 202 toward arched segment 200. Proximate arched segment 200, medial side 228 bows inward toward rear segment 179, at which point medial side 228 extends in a straight line toward second end 222. Lateral side 226 begins at third end 224 and curves outward along toe segment 202 toward arched segment 200. Proximate arched segment 200, lateral side 226 bows inward toward rear segment 179, at which point medial side 226 extends in a straight line toward second end 222.

[0083] Referring to FIG. 12 , plate 170 may also be defined by a curved portion 250 extending through the forefoot region 108 and midfoot region 110 of footwear 100 and a flat region 252 extending through the heel region 112 of footwear 100 to second end 222. Flat region 252 is flat and substantially flat such that when plate 170 is positioned within footwear 100, flat region 252 is horizontal within about 10 degrees or 5 degrees relative to the ground, or reference plane 254 (see FIG. 12 ). Flat region 252 may also be at a height H1 relative to reference plane 254. In some embodiments, height H1 may range from about 1 millimeter to about 50 millimeters. In other embodiments, height H1 may range from about 5 millimeters to about 35 millimeters, or from about 10 millimeters to about 20 millimeters.

[0084] 12 , the curved portion 250 may include one or more radii of curvature. For example, in this embodiment, the curved portion 250 includes a front curved portion 256, an inner curved portion 258, and a back curved portion 260, each having a radius of curvature. The front curved portion 256 may extend between the first end 220 and an apex 262, which in this embodiment is the location along the plate 170 where the plate 170 meets the reference plane 254. The inner curved portion 258 may be adjacent to the front curved portion 256 and may extend between the apex 262 and a transition point 264, which is defined as the location along the plate where the angle of the plate 170 relative to the reference plane 254 changes. For example, in this embodiment, the angle of the curved portion 250 relative to the reference plane 254 increases at the transition point 264. The back curved portion 260 is adjacent to the inner curved portion 258 and extends from the transition point 264 to the flat region 252 of the plate 170.

[0085] 12 , the forward curved portion 256, the medial curved portion 258, and the rear curved portion 260 may be defined by lengths L2, L3, and L4 and angles A1, A2, and A3, respectively. Length L2 is measured along the reference plane 254 between the apex 262 and the front end 220 of the plate 170, length L3 is measured along the reference plane 254 between the apex 262 and the transition point 264, and length L4 is measured along the reference plane 254 between the transition point 264 and the front end 266 of the rear segment 179 of the plate 170. As further shown in FIG. 12 , the rear segment 179 or flat portion 252 may have a length L5 measured from its front end 266 to the second end 222. In some embodiments, the length L2 may be approximately ten percent (10%), 20%, 30%, or 40% of the total length L1 of the plate 170, the length L3 may be approximately 10%, 20%, 30%, 40%, 50%, or 60% of the total length L1 of the plate 170, the length L4 may be approximately 10%, 20%, 30%, 40%, 50%, or 60% of the total length L1 of the plate 170, and the length L5 of the flat portion 179 may be approximately 10%, 20%, 30%, or 40% of the total length L1 of the plate 170. In alternative embodiments, curved portion 250 may not include transition point 264, such that plate 170 includes only a forward portion 256 extending from apex 262 to forward end 220 of plate 170, and a rearward portion (not shown) extending from apex 262 to forward end 266 of rear segment 179. In such embodiments, the length of the rearward portion may be approximately equal to the sum of length L3 and length L4.

[0086] As previously mentioned, the forward curve 256, inner curve 258, and rear curve 260 of the plate 170 may also be defined by angles A1, A2, and A3, respectively. Angle A1 of the forward curve 256 may be defined as the angle at which the forward portion 256 extends from the apex 262 toward the front end 220. Or, stated another way, angle A1 may be defined as the angle between the reference plane 254 and a linear plane 268 extending between the apex 262 and the front end 220. Angle A1 may be between about 3 degrees and about 45 degrees, or between about 5 degrees and about 20 degrees, or between about 10 degrees and about 20 degrees.

[0087] Similarly, angle A2 of inner curve 258 may be defined as the angle at which inner curve 258 extends from apex 262 toward posterior segment 179 of plate 170. Or, stated another way, angle A2 may be defined as the angle between reference plane 254 and a second linear plane 270 extending between apex 262 and transition point 264. Angle A2 may be between about 3 degrees and about 45 degrees, or between about 5 degrees and about 20 degrees, or between about 10 degrees and about 20 degrees. In some embodiments, angle A2 of inner curve 258 and angle A1 of forward curve 268 are substantially equal to one another.

[0088] Angle A3 of posterior curve 260 may be defined as the angle at which posterior curve 260 extends toward posterior segment 179, and may be defined as the angle between reference plane 254 and a third linear plane 272 extending between transition point 264 and anterior end 266 of posterior segment 179 of plate 170. Angle A3 may be between about 5 degrees and about 70 degrees, or between about 20 degrees and about 50 degrees, or between about 30 degrees and about 50 degrees. In some embodiments, angle A3 of posterior curve 260 is greater than angles A1, A2 of inner curve 258 and anterior curve 256.

[0089] FIG. 48 illustrates another configuration of plate 1200. Features of plate 1200 that are the same as those shown and described with respect to plate 170 are designated with like reference numerals. Plate 1200 may be defined by posterior segment 179, arched segment 200, and toe segment 202. Plate 1200 may also include an opening 1202 proximate first end 220 of plate 1200 and defined by an interior wall 1204. The opening may be circular or oval and may be completely contained within toe segment 202, completely contained within arched segment 200, or extend from toe segment 202 into arched segment 200.

[0090] Plate 170 may be formed from densified wood or a densified wood panel formed by chemically treating natural wood to remove lignin or hemicellulose therefrom or compressing natural wood, as described herein. In some embodiments, plate 170 may be formed from a composite of densified wood and a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, or a thermoplastic olefin. In some embodiments, plate 170 may be formed from a composite of densified wood and one or more fibers, such as carbon fiber, aramid fiber, boron fiber, glass fiber, natural fiber, and polymer fiber, or a combination thereof. In these embodiments, the densified wood and / or fibers may be affixed or bonded to a substrate or a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic polyolefin, or a thermoplastic elastomer, by stitching or adhesive. In other embodiments, plate 170 may be formed from a unidirectional tape including carbon fiber, aramid fiber, boron fiber, glass fiber, polymer fiber, or the like. In other embodiments, plate 170 may be formed from a composite with at least one layer of densified wood.

[0091] In some embodiments, one or more materials of plate 170 may have a stiffness (e.g., tensile strength) defined by Young's modulus. For example, in certain embodiments, one or more materials forming plate 170 may have a Young's modulus of at least about 25 gigapascals (GPa), at least about 40 GPa, or at least about 70 GPa, or at least about 85 GPa, or at least about 200 GPa. In further embodiments, one or more materials forming plate 170 may have a Young's modulus of about 25 GPa to about 200 GPa, or about 25 GPa to about 80 GPa, or about 25 GPa to about 70 GPa, or about 50 GPa to about 75 GPa.

[0092] In some embodiments, part or all of plate 170 is formed from densified wood having a Young's modulus of about 10 GPa to about 70 GPa, about 12 GPa to about 60 GPa, about 18 GPa to about 58 GPa, about 25 GPa to about 55 GPa, or about 35 GPa to about 50 GPa. In some embodiments, part or all of plate 170 is formed from densified wood having a Young's modulus of at least 10.0 GPa, at least 12.0 GPa, at least 15.0 GPa, at least 20.0 GPa, at least 25.0 GPa, at least 30.0 GPa, at least 40.0 GPa, at least 50.0 GPa, or at least 55.0 GPa.

[0093] In some embodiments, plate 170 and its stiffness may be selected and designed for a particular user. For example, the stiffness of plate 170 may be selected based on the user's particular muscle strength, tendon flexibility, or joint flexibility. In further embodiments, the stiffness of plate 170 may vary such that one portion of plate 170 is stiffer than another portion of plate 170. For example, in instances where the user pronates, the medial second toe segment 214 of plate 170 may be stiffer than the first toe segment 212, arched portion 200 (or, individually, medial curve 258 and / or posterior curve 260), and posterior segment 179 of plate 170. In other embodiments, if additional support is desired in the arch or midfoot region 110 of footwear 100, arched segment 200 (or, individually, medial curve 258 and / or rear curve 260) of plate 170 may be stiffer than toe segment 202 and rear segment 179 of plate 170. Essentially, it is contemplated that first toe segment portion 212, second toe segment portion 214, arched segment 200 (or, individually, medial curve 258 and / or rear curve 260), and rear segment 179 may each have an individual stiffness within the aforementioned ranges and that is greater or less than the stiffness of the other segments of plate 170. In alternative embodiments, the stiffness of plate 170 may be uniform and constant between first toe segment portion 212, second toe segment portion 214, arched segment 200, and rear segment 179.

[0094] In some embodiments, the stiffness of plate 170 may be altered by increasing or decreasing the number of layers of densified wood therein. In some embodiments, certain areas of plate 170 may include more layers of densified wood to increase stiffness. In some embodiments, the stiffness of plate 170 may be altered by combining densified wood with one or more additional materials to achieve a desired stiffness.

[0095] Plate 170 may also include a uniform or substantially uniform thickness between about 0.5 millimeters (mm) and about 3.0 mm, or between about 0.5 mm and about 2.0 mm, or between about 0.7 mm and about 1.0 mm. In other embodiments, plate 170 may have a non-uniform thickness or a thickness that varies across plate 170. For example, similar to the stiffness of the plate 170, the thickness of the first toe segment portion 212 may be different from the thickness of the second toe segment portion 214, the arched segment 200 (or individually, the medial curve portion 258 and / or the posterior curve portion 260), and / or the posterior segment 179; the second toe segment portion 214 may be different from the thickness of the first toe segment portion 214, the arched segment 200, and / or the posterior segment 179; the arched segment 200 may be different from the thickness of the first toe segment portion 212, the second toe segment portion 214, and / or the posterior segment 179; or the posterior segment 179 may have a different thickness from the thickness of the first toe segment portion 212, the second toe segment portion 214, and / or the arched segment 200. Essentially, the thickness of first toe segment portion 212, second toe segment portion 214, arch segment 200, or rear segment 179 may be individually selected when plate 170 is formed. In certain embodiments, the thickness of plate 170 and its regions may be selected for a particular user and their particular muscle strength, tendon flexibility, or joint flexibility. In these embodiments, the thickness of plate 170 and the individual thicknesses of its segments 179, 200, 212, 214 may range from about 0.5 mm to about 3.0 mm, or from about 0.5 mm to about 2.0 mm, or from about 0.7 mm to about 1.0 mm.

[0096] 13 , the first toe segment 212 may be positioned proximate to and support the fourth distal and / or fourth proximal phalanges 300 and the fifth distal and / or fifth proximal phalanges 302. Accordingly, the characteristics of the first toe segment 212 may be tailored to provide an optimal or desired amount of support, resilience, or spring force to a particular region of the user's foot. Additionally, the second toe segment 214 may be positioned proximate to and support the first distal and / or first proximal phalanges 304 and the second distal and / or second proximal phalanges 306. Accordingly, the characteristics of the first toe segment 212 may be tailored to provide an optimal or desired amount of support, resilience, or spring force to a particular region of the user's foot. The arch segment 200 may be positioned in proximity to and support the first metatarsal 308, the second metatarsal 310, the third metatarsal 312, the fourth metatarsal 314, and / or the fifth metatarsal 316, as well as the cuboid 318, the navicular 320, and / or the cuneiform 322, such as the lateral cuneiform, the intermediate or middle cuneiform, and / or the medial cuneiform, of the user's foot. Accordingly, the characteristics of the arch segment 200 may be tailored to provide an optimal or desired amount of support, resilience, or spring force to a particular region of the user's foot. Finally, the posterior segment 179 may be positioned in proximity to and support the heel or calcaneus 324 of the user's foot, and therefore, the characteristics of the posterior segment 179 may be tailored to provide an optimal or desired amount of support, resilience, or spring force to a particular region of the user's foot. For example, if a runner has a toe strike, i.e., if the runner places the weight of the impact on the toes and ball of the foot (e.g., distal and / or proximal phalanges 300-306), then the majority of the user's weight and force when running may be applied to the first toe segment 212 and the second toe segment 214 of the plate 170. Thus, the first toe segment 212 and the second toe segment 214 may be designed to provide the necessary stiffness to support the user's foot when running, thereby reducing energy dissipation.Additionally, in this embodiment, arched segment 200 and rear segment 179 of plate 170 may be constructed from a lightweight material because minimal weight or force is applied to these areas and therefore less support is needed in these particular areas for runners with a forefoot strike. Alternatively, if the runner has a heel strike or midfoot strike, first toe segment portion 212, second toe segment portion 214, arched segment 200, and rear segment 179 may be constructed from a rigid material to provide support to the user's foot throughout the stride and during contact with the ground.

[0097] In other embodiments, as discussed further herein, the size and shape of the plate 170 may be varied to provide desired support and structure to the wearer's foot. For example, in this particular embodiment, the first toe segment portion 212 may have a width W2 (see FIG. 10 ). The width W2 may be defined as the distance between the outer side 226 of the plate 170 and the inner walls 216, 218 of the cleft 210 on the third distal end 224 of the plate 170. Additionally, the second toe segment portion 214 may have a width W3 defined as the distance between the inner side 228 of the plate 170 and the inner wall 218 of the cleft 210. Additionally, the cleft 210 may have a width W4 defined as the distance between the first toe segment portion 212 and the second toe segment portion 214. In some embodiments, the width W4 of the cleft 210 may be increased and the widths of the first toe segment portion 212 and the second toe segment portion 214 may be decreased as discussed further herein (see, e.g., FIGS. 19 and 20).

[0098] In some embodiments, widths W2 and W3 may individually be about 2.5 millimeters (mm) to about 100 mm, or about 5 mm to about 50 mm, or about 10 mm to about 30 mm, or about 15 mm to about 30 mm, or about 20 mm to about 30 mm, or about 25 mm. Additionally, width W4 of cleft 210 may be about 2.5 mm to about 100 mm, or about 5 mm to about 50 mm, or about 10 mm to about 30 mm, or about 15 mm to about 30 mm, or about 20 mm to about 30 mm, or about 30 mm to about 70 mm, or about 30 mm to about 50 mm, or about 35 mm to about 45 mm.

[0099] 19 and 20 provide a sole structure 400 according to a second embodiment of the present disclosure. In this embodiment, sole structure 400 includes an outsole 402, a midsole cushioning member 404, and a plate 406. Additionally, while FIGS. 19 and 20 show only sole structure 400, it should be understood by those skilled in the art that sole structure 400 may be connected to an upper, such as upper 102, to form footwear. Accordingly, an embodiment of upper 102 in combination with sole structure 400 is envisioned, where upper 102 may be attached to sole structure 400 and, together with sole structure 400, may define an internal cavity into which a foot may be inserted.

[0100] The configuration of sole structure 400 is substantially similar to sole structure 104, except that sole structure 400 does not include heel cushioning member 172 and heel support collar 174, but instead includes an outsole 402, a midsole cushioning member 404, and a plate 406 having a first toe segment portion 408 and a second toe segment portion 410.

[0101] As previously described herein, the width W2 of the first toe segment portion 212, the width W3 of the second toe segment portion 214, and the width W4 of the cleft 210 may vary and may depend on the desired support needed for the sole structure 104. For example, if relatively less support is needed on the lateral side 124 of the sole structure 104 and relatively less support is needed on the medial side 126 of the sole structure 104, the width W4 of the cleft 210 may be increased, while the width W2 of the first toe segment portion 212 and the width W3 of the second toe segment portion 214 may be decreased. For example, with particular reference to FIGS. 10 and 20 , the width of the first toe segment portion 408 is less than the width W2 of the first toe segment portion 212, the width of the second toe segment portion 410 is less than the width W3 of the second toe segment portion 410, and the width of the cleft 412 is greater than the width W4 of the cleft 210.

[0102] 21 provides a sole structure 450 including a midsole cushioning member 452, a plate 454, and an outsole 456 according to a third embodiment of the present disclosure. While FIG. 21 shows only the sole structure 450, it should be understood that the sole structure 450 may be connected to an upper, such as the upper 102, to form footwear. Accordingly, aspects of the upper 102 in combination with the sole structure 450 are envisioned, where the upper 102 may be attached to the sole structure 450 and, together with the sole structure 450, may define an interior cavity into which a user's foot may be inserted.

[0103] In this embodiment, midsole cushioning member 452 may be adjacent to and overlying outsole 456 in the forefoot region, midsole region, and heel region. Midsole cushioning member 452 may also include a recess 458 in communication with plate 454. In other words, recess 458 of midsole cushioning member 452 may embed, encapsulate, or surround at least a portion of plate 170. Thus, recess 458 of midsole cushioning member 452 may also define the shape and size of plate 170.

[0104] As mentioned above, sole structure 450 may include plate 454 disposed therein. In certain embodiments, plate 454 may be disposed adjacent to and between outsole 456 and midsole cushioning member 452 in a forefoot region of the footwear, such that plate 454 is vertically below midsole cushioning member 452 in the midfoot region of the footwear and / or vertically below midsole cushioning member 452 in the midfoot region of the footwear. In other words, plate 454 may be disposed between midsole cushioning member 452 and outsole 456 in the forefoot region and / or midfoot region. Further, in this particular embodiment, the depth of recess 458 in the forefoot region is less than the depth of recess 458 in the heel region of sole structure 450. As a result, plate 454 is positioned within but extends from recess 458 in the forefoot region of sole structure 450 when assembled, such that outsole 456 engages or contacts plate 454 in the forefoot region. However, because the depth of recess 458 is greater than the thickness of plate 454 in the heel region, in this embodiment, midsole cushioning member 452 completely surrounds plate 454 and, when assembled, a gap (not shown) exists between plate 454 and outsole 456.

[0105] In this embodiment, plate 454 may also be defined by a rear segment 460, an arch segment 462, and a toe segment 464. When assembled, rear segment 460 may extend through at least a portion of the heel region of sole structure 450 and may correspond to a portion of plate 454 positioned near the rear of the foot, including the heel or calcaneus, ankle, or Achilles tendon. Arch portion 462 of plate 454 is proximate and adjacent to rear segment 460 and corresponds to a portion of plate 454 located near the midfoot region of the footwear that encases the arch of the foot along with the bridge of the foot. Toe segment 464 of the plate is proximate and adjacent to arch segment 462 and corresponds to a portion of the foot that includes the toes, the ball of the foot, and the joints connecting the metatarsals to the toes or phalanges (i.e., the metatarsophalangeal joints).

[0106] The toe segment 464 of the plate 454 may also include a cleft 466 that bifurcates the toe segment 464 into a first toe segment portion 468 on the lateral side of the plate and a second toe segment portion 470 on the medial side of the plate 454 .

[0107] 21 , the arched portion 462 may be curved or bowed such that the toe segment 464 has a relative position below the arched portion 462 and / or rear segment 460 of the plate 454 when the plate 454 is positioned within the sole structure 450. In other words, when assembled, the toe segment 464 of the plate 454 is closer to the outsole 456 compared to the rear segment 460 of the plate 454, and the rear segment 460 of the plate 454 is closer to the insole or upper surface (not shown) of the midsole cushioning member 452 compared to the toe segment 464 of the plate 454. In these embodiments, the arched portion 462 curves upward toward the rear segment 460, which is relatively flat. In certain embodiments, the rear segment 460 is substantially flat such that the rear segment 460 is horizontal to within about 10 degrees or within 5 degrees of the ground, or a reference plane, when the plate 454 is positioned within the sole structure 450. However, unlike sole structures 104, 400, midsole cushioning member 452 does not include an opening through which a portion of plate 454 extends, and therefore no portion of plate 454 is above midsole cushioning member 452. Rather, in this embodiment, the entire length of plate 454 is below midsole cushioning member 452 and is disposed between midsole cushioning member 452 and outsole 456.

[0108] As discussed above in connection with FIGS. 1-21 , toe segments, e.g., toe segment 202, 464 of plate 170, 406, 454, may be modified to enhance and alter the support for sole structure 104, 400, 450, and thus, the support provided to the forefoot region of a user's foot. Similarly, in alternative embodiments, rear segments, e.g., rear segment 179, 460 of plate 170, 406, 454, may be modified to alter or optimize the support provided to the heel region of sole structure 104, 400, 450. In other words, rear segments of plate 170, 406, 454 may be modified to increase or decrease support for the heel region of a user's foot. For example, FIGS. 22 and 23 illustrate further embodiments of sole structure 500 (see FIG. 22 ) and sole structure 600 (see FIG. 23 ), in which the rear segments of the plates are modified to provide optimized support to the heel region of the footwear.

[0109] 22, sole structure 500 may include midsole cushioning member 502, plate 504, heel cushioning member 506, and outsole 508. With reference to FIG. 23, sole structure 600 may include upper midsole cushioning member 602, plate 604, lower midsole cushioning member 606, heel support collar 608, and outsole 610. In these embodiments, as with prior embodiments, while FIGS. 22 and 23 only illustrate sole structures 500, 600, it should be understood that sole structures 500, 600 may be connected to an upper, such as upper 102, to form footwear.

[0110] 22 and 23 , sole structures 500, 600 include plates 504, 604 having clefts 510, 610 that bifurcate the toe segment into a first toe segment portion 512, 612 lateral to the plate 504, 604 and a second toe segment portion 514, 614 medial to the plate 504, 604, and second clefts 516, 616 that bifurcate the posterior segment into a first rear segment portion 518, 618 lateral to the plate 504, 604 and a second rear segment portion 520, 620 medial to the plate 504, 604. In these embodiments, the second clefts 516, 616 may be defined by inner walls 522, 622, which may be generally curved or parabolic. In some embodiments, the size of the first rear segment portion 518, 618 and / or the second rear segment portion 520, 620 may provide support to the heel region of the sole structure 500, 600.

[0111] Further, similar to plate 170 of sole structure 104, plates 504, 604 may include a flat portion and a curved portion having a forward curved portion, an inner curved portion, and / or a rearward curved portion. For example, as shown in FIG. 23 , plate 604 may include a flat portion 624 and a curved portion having a forward curved portion 626, an inner curved portion 628, and a rearward curved portion 630. Lower midsole cushioning member 606 may also include a support surface 632 that projects upwardly from an upper surface 634 of lower midsole cushioning member 606. In this embodiment, support surface 632 contacts or engages the lower surfaces of flat portion 624, rearward curved portion 630, and inner curved portion 628.

[0112] 24-26 provide another sole structure 700 including a midsole cushioning member 702, a plate 704, and an outsole 706 according to another embodiment of the present disclosure. In this particular embodiment, the plate 704 includes a base 708 and medial and lateral arms 710, 712. Additionally, the midsole cushioning member 702 may include an opening 714 through which the base 708 may pass. For example, as shown in FIGS. 25 and 26, the base 708 may be folded onto itself and inserted through the opening 714. Once the base 708 is inserted through the opening 714, the base 708 may be positioned within the recess 716.

[0113] FIG. 27 shows a top view of plate 800 according to another embodiment of the present disclosure, which may be characterized and defined in a manner similar to plate 170 previously described herein. Additionally, FIGS. 28-35 show footwear 802 or sole structure 804 thereof including plate 800. Footwear 802 or sole structure 804 thereof may also include upper midsole cushioning member 806, heel support collar 808, plate 800, lower midsole cushioning member 810, outsole 812, and upper 813 according to yet another aspect of the present disclosure. Similar to the embodiment previously described herein, plate 800 may be defined by rear segment 814 (see FIG. 30), arch segment 816 (see FIG. 30), and toe segment 818 (see FIG. 30). 30 , rear segment 814, when incorporated therein, may extend through at least the heel region of footwear 802 and may correspond to a portion of plate 800 positioned near the rear of the foot, as previously described herein. Arched segment 816 of plate 800 is proximate and adjacent to rear segment 814 and corresponds to a portion of plate 800 positioned near the midfoot region of article of footwear 802 that encases the arch of the foot along with the bridge of the foot. Toe segment 818 of plate 800 is proximate and adjacent to arched segment 816 and corresponds to a portion of plate 800 positioned near the forefoot region of footwear 802.

[0114] Similar to plate 170, toe segment 818 of plate 800 may also include a cleft 820 that bifurcates toe segment 818 into a first toe segment portion 822 on the outside of plate 800 and a second toe segment portion 824 on the inside of plate 800. First toe segment portion 822, second toe segment portion 824, and cleft 820 may have similar characteristics as first toe segment portion 212, second toe segment portion 214, and cleft 210. For example, first toe segment 822, second toe segment 824, and cleft 820 may have widths equal to widths W2, W3, and W4, respectively, as previously described herein. As best shown in FIG. 27 , plate 800 may also be defined by a first end 826 that is the distal end of second toe segment portion 824, a second end 828 that is the distal end of rear segment 814, and a third end 830 that may be the distal end of first toe segment portion 822. A length L6 of plate 800 may be defined by the distance between first end 826 and second end 828 and may be equal to or less than the length of a midsole, such as upper midsole cushioning body 806, of the footwear. Plate 800 may also include a lateral side 832 and a medial side 834 that extend between first end 826 and second end 828. The distance between lateral side 832 and medial side 834 may also define a width W5 of plate 800, which may vary between first end 826 and second end 828 of plate 800.

[0115] 27 , medial side 834 begins at first end 826 and curves outward along toe segment 818 toward arched segment 816. Proximate arched segment 816, medial side 834 curves inward toward rear segment 814, at which point medial side 834 curves outward again. Lateral side 832 begins at third end 830 and curves outward along toe segment 818 toward arched segment 816. Proximate arched segment 816, lateral side 832 curves inward toward rear segment 814, at which point medial side 832 curves outward again.

[0116] 30 , plate 800 may also include a curved portion 816 that extends through the toe and midfoot regions of footwear 802, and a flat region 814 that extends through the heel region of footwear 802 to a second end 828. Flat region 814 is substantially flat such that when plate 800 is placed within footwear 802, flat region 814 is horizontal to within about 10 degrees or 5 degrees of the ground.

[0117] Similar to plate 170, toe segment portion 818 and curved portion 816 may include one or more radii of curvature. For example, in this embodiment, curved portion 816 may be angled similarly to rear curved portion 256, and toe segment portion 818 may be angled similarly to medial curved portion 256 and / or rear curved portion 260. Toe segment portion 818 and curved portion 816 may each be defined by a length, such as length L7 or L8, and an angle, such as angles A1, A2, and / or A3, as previously described herein. Rear segment 814 may also be defined by a length L9, similar to length L5.

[0118] As previously described herein, a portion or all of plate 800, or plates 170, 406, 454, 504, 604, 704, may be formed from densified wood. In some embodiments, plate 800, or plates 170, 406, 454, 504, 604, 704, may be formed from a composite of densified wood and a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, or a thermoplastic olefin. However, in certain embodiments, plate 800, or plates 170, 406, 454, 504, 604, 704, may be formed from a composite or one or more layers of densified wood with fibers, such as carbon fiber, aramid fiber, boron fiber, glass fiber, and polymer fiber, or a combination thereof. In these embodiments, the densified wood and / or fibers may be affixed or bonded to a substrate or thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic polyolefin, or a thermoplastic elastomer, by stitching or adhesive bonding. In other embodiments, plate 800, or plates 170, 406, 454, 504, 604, 704 may be formed from unidirectional tapes including densified wood, carbon fiber, aramid fiber, boron fiber, glass fiber, polymer fiber, and the like.

[0119] In some embodiments, one or more materials of plate 800, or plates 170, 406, 454, 504, 604, 704, may have a stiffness (e.g., tensile strength) defined by Young's modulus. For example, in certain embodiments, one or more materials forming plate 800, or plates 170, 406, 454, 504, 604, 704 may have a Young's modulus of at least about 25 gigapascals (GPa), at least about 40 GPa, or at least about 70 GPa, or at least about 85 GPa, or at least about 200 GPa. In further embodiments, one or more materials forming plate 800 may have a Young's modulus of about 25 GPa to about 200 GPa, or about 25 GPa to about 80 GPa, or about 25 GPa to about 70 GPa, or about 50 GPa to about 75 GPa. In some embodiments, plate 800, or plate 170, 406, 454, 504, 604, 704, and their stiffness may be selected and designed for a particular user. For example, the stiffness of plate 800, or plate 170, 406, 454, 504, 604, 704 may be selected based on the user's particular muscle strength, tendon flexibility, or joint flexibility. In further embodiments, the stiffness of plate 800, or plate 170, 406, 454, 504, 604, 704 may be varied, as described previously herein, such that one portion of plate 800, or plate 170, 406, 454, 504, 604, 704, is stiffer than another portion thereof. In some embodiments, part or all of plate 800, or plates 170, 406, 454, 504, 604, 704, are formed from densified wood having a Young's modulus of at least 10.0 GPa, at least 12.0 GPa, at least 15.0 GPa, at least 20.0 GPa, at least 25.0 GPa, at least 30.0 GPa, at least 40.0 GPa, at least 50.0 GPa, or at least 55.0 GPa.

[0120] Plate 800, or plate 170, 406, 454, 504, 604, 704, may also include a uniform or substantially uniform thickness of about 0.5 millimeters (mm) to about 3.0 mm, or about 0.5 mm to about 2.0 mm, or about 0.7 mm to about 1.0 mm. In other embodiments, plate 800, or plate 170, 406, 454, 504, 604, 704, may have a non-uniform thickness or thickness that varies across plate 800, or across plate 170, 406, 454, 504, 604, 704, as previously described herein.

[0121] 30-35, plate 800 may be adjacent to and disposed between upper midsole cushioning member 806 and lower midsole cushioning member 810. Upper midsole cushioning member 806 may include a recess into which plate 800 may be fitted or secured such that upper midsole cushioning member 806 at least partially encases plate 800. A portion of lower cushioning member 810 may extend into the recess of upper cushioning member 806 (see, for example, FIG. 34).

[0122] The upper midsole cushioning member 806 and / or the lower midsole cushioning member 810 may be constructed from EVA, TPU, TPE, combinations thereof, or similar types of materials. For example, in some embodiments, the upper cushioning member 806 and / or the lower cushioning member 810 may be constructed from ESS material, EVA foam (e.g., PUMA® ProFoam Lite TM, IGNITE foam), polyurethane, polyether, olefin block copolymer, thermoplastic material (e.g., thermoplastic polyurethane, thermoplastic elastomer, thermoplastic polyolefin, etc.), or supercritical foam. Upper midsole cushioning member 806 and / or lower midsole cushioning member 810 may be a single polymer material or a blend of materials such as EVA copolymer, thermoplastic polyurethane, polyester block amide (PEBA) copolymer, and / or olefin block copolymer. Furthermore, upper cushioning member 806 and / or lower midsole cushioning member 810 may be formed from a supercritical foaming process in which a supercritical gas, e.g., CO2, N2, or a mixture thereof, is used to foam a material, e.g., EVA, TPU, TPE, or a mixture thereof. In such embodiments, upper midsole cushioning member 806 and / or lower midsole cushioning member 810 may be manufactured using a process carried out in an autoclave, an injection molding machine, or any sufficiently heated / pressurized vessel capable of processing the mixture of a supercritical fluid (e.g., CO, N, or a mixture thereof) with a material (e.g., TPU, EVA, a polyolefin elastomer, or a mixture thereof), preferably in a molten state. For example, in an exemplary process, a solution of the supercritical fluid is mixed with the molten material. This mixture is pumped or injected into a pressurized vessel, after which the pressure in the vessel is released, causing the molecules of the supercritical fluid to rapidly turn into a gas, forming small pockets within the material and expanding the material into a foam that may be used as upper midsole cushioning member 806 and / or lower midsole cushioning member 810. In further embodiments, the upper midsole cushioning member 806 and / or the lower midsole cushioning member 810 may be formed using alternative methods known in the art, including the use of an expansion press, an injection machine, a pellet expansion method, a cold foaming method, a compression molding technique, a die cutting method, or any combination thereof.In certain embodiments, upper midsole cushioning member 806 and / or lower midsole cushioning member 810 may be formed using a process that includes an initial foaming step in which a supercritical gas is used to foam a material, and a second step in which the foam material is compression molded or die-cut into a particular shape. For example, upper midsole cushioning member 806 and / or lower midsole cushioning member 810 may be formed using a process that includes an initial foaming step in which a supercritical fluid is used to foam a material, and then a second step in which the foam material is compression molded to form the concave surface of upper midsole cushioning member 806.

[0123] In further embodiments, upper midsole cushioning member 806 and / or lower midsole cushioning member 810 may be bladders enclosing a plurality of beads or pellets formed from thermoplastic polyurethane, thermoplastic elastomer, or supercritical foam. For example, upper midsole cushioning member 806 and / or lower midsole cushioning member 810 may define an interior void (not shown) that receives a pressurized fluid or a plurality of beads or pellets, such as the hollow space filled with a plurality of plastic bodies as described above in International Publication No. WO 2017 / 097315, filed December 7, 2015.

[0124] Similar to heel support collar 174 of sole structure 104, sole structure 804 may include heel support collar 808. Heel support collar 808 may be formed from a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, or a thermoplastic olefin. Further, in certain embodiments, heel support collar 808 may have a hardness of about 10 Shore A to about 90 Shore A. In some embodiments, heel support collar 808 may have a hardness or stiffness value that is greater than the hardness or stiffness value of upper midsole cushioning member 806 and / or lower midsole cushioning member 810.

[0125] 36-38 show another sole structure 900 for footwear. In this embodiment, the sole structure 900 includes an outsole 902, a plate 904, a heel cushioning member 906, a heel support collar 908, and a midsole cushioning member 910.

[0126] In this embodiment, the plate 904 may include a lower base 912 having a slope with an angle of about 10° to 45° or about 20° to about 30°. In other words, with respect to a horizontal plane, the lower base 912 of the plate 904 slopes upward as it extends toward the heel region of the sole structure 900. The plate may also include an arched, curved, or C-shaped rear portion 914 connecting the lower base 912 to an upwardly extending flange 916. The midsole cushioning member 910 may also include an upwardly extending sidewall 918, as shown in FIG. 36 , and the upwardly extending flange 916 may wrap around the sidewall 918 when the sole structure 900 is assembled. Additionally, the heel support collar 908 may wrap around the flange 916 of the plate 904 when the sole structure 900 is assembled. Thus, in these embodiments, a portion of the plate 904 may be positioned both above and below the midsole cushioning member 910 at certain locations along the sole structure 900. For example, near the heel region of the sole structure 900, the base 912 of the plate 904 is positioned below the midsole cushioning member 910 and the flange 916 of the plate 904 is positioned above the midsole cushioning member 910.

[0127] As previously described herein, part or all of plate 904 may be formed from densified wood. In some embodiments, plate 904 may be formed from a composite of densified wood and a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, or a thermoplastic olefin. Essentially, plate 904 may be constructed from similar materials and have similar properties as plates 170, 406, 454, 504, 604, 704, and 800 previously described herein.

[0128] The midsole cushioning member 910 may be constructed from materials similar to those of the midsole cushioning member 176. For example, the midsole cushioning member may be constructed or composed of EVA, TPU, TPE, combinations thereof, or similar types of materials. Additionally, as described previously herein, the midsole cushioning member 910 may be formed from a supercritical foaming process in which a supercritical gas, such as CO2, N2, or a mixture thereof, is used to foam a material, such as EVA, TPU, TPE, or a mixture thereof. In yet another embodiment, the midsole cushioning member 910 may be an air bladder enclosing a plurality of beads, such as a plurality of spherical or elliptical beads or pellets, formed from thermoplastic polyurethane, thermoplastic elastomer, or supercritical foam. For example, the midsole cushioning member 910 may define an interior void (not shown) that receives a pressurized fluid or a plurality of elliptical or spherical beads, such as a hollow space filled with a number of plastic bodies, as described previously herein.

[0129] In this embodiment, sole structure 900 may also include a heel cushioning member 906, which may be positioned adjacent to and on outsole 902 in the heel region and partially in the midfoot region. In other words, heel cushioning member 906 may be adjacent outsole 902 and may extend from the heel end of sole structure 900, through the heel region, and partially through the midfoot region. Heel cushioning member 906 may be constructed from ethylene vinyl acetate (EVA), copolymers thereof, or similar types of materials. For example, in some embodiments, heel cushioning member 906 is constructed from an EVA-Solid-Sponge ("ESS") material, EVA foam (e.g., PUMA® ProFoam Lite TM, IGNITE foam), polyurethane, polyether, olefin block copolymer, thermoplastic material (e.g., thermoplastic polyurethane, thermoplastic elastomer, thermoplastic polyolefin, etc.), or supercritical foam. Heel cushion member 906 may be a single polymer material or a blend of materials, such as EVA copolymer, thermoplastic polyurethane, polyether block amide (PEBA) copolymer, and / or olefin block copolymer. In yet another embodiment, heel cushion member 906 may be an air bladder enclosing a plurality of beads or pellets, such as a plurality of spherical, elliptical, or other shaped beads or pellets, formed from thermoplastic polyurethane, thermoplastic elastomer, or supercritical foam. For example, heel cushion member 906 may define an interior void (not shown) that receives pressurized fluid or a plurality of elliptical, spherical, or other shaped beads or pellets, as previously described herein.

[0130] Similar to heel support collar 174, sole structure 900 may also include a heel support collar 908 disposed above midsole cushioning member 900. Heel support collar 908 may be formed from a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, or a thermoplastic olefin.

[0131] 39-45 provide a sole structure 1000 according to another embodiment of the present disclosure. While FIGS. 39-45 show only sole structure 1000, it should be understood by those skilled in the art that top surface 1014 of sole structure 1000 may be connected to an upper, such as upper 102, to form footwear. Accordingly, aspects of upper 102 in combination with sole structure 1000 are envisioned, where upper 102 may be attached to sole structure 1000 and, together with sole structure 1000, may define an interior cavity into which a foot may be inserted.

[0132] In the embodiment shown in Figures 39-45, the sole structure 1000 includes a soleplate 1002 comprised of an upper surface 1014, a bottom surface 1016, and one or more protrusions 1004, 1010 extending downwardly from the bottom surface 1016. The protrusions 1004, 1010 of the soleplate 1002 are configured to reversibly or irreversibly attach studs 1006, 1012 thereto. The studs 1006, 1012 attached to the soleplate are adapted to engage with and be partially inserted into the ground when worn by a user. The soleplate 1002 may include additional structural features, such as ridges 1008 or flex grooves 1018, 1020, to support or modify the structure, flexibility, or rigidity of the soleplate 1002. Although only a single sole structure 1000 is shown, i.e., a sole structure for footwear worn on a user's right foot, it should be understood that the concepts disclosed herein are applicable to a pair of shoes (not shown), including a left shoe and a right shoe that can be sized and shaped to receive a user's left and right feet, respectively. However, for ease of disclosure, although a single shoe is referenced to describe aspects of the present disclosure, the disclosure herein that references sole structure 1000 is applicable to both the left and right shoes.

[0133] Many shapes and configurations of protrusions 1004, 110 and studs 1006, 1012 are known in the art and may be optimized for the wearer, the terrain, or the type of activity for which the footwear will be used. In some embodiments, the soleplate 1002 includes at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 12, at least 15, at least 18, at least 20, at least 25, at least 30, or at least 40 protrusions 1006, 1012 and studs attached thereto. In some embodiments, the studs 1006, 1012 may be cylindrical, conical, prismatic, or winged. Similarly, the studs may be formed from any suitable material, including, but not limited to, rubber, metal, or a thermoplastic material such as a thermoplastic polyurethane, a thermoplastic elastomer, or a thermoplastic olefin. The studs 1006, 1012 may be attached to the soleplate 1002 through the protrusions 1004, 1010 by any means known in the art, including but not limited to adhesive or interlocking threads.

[0134] In some embodiments, the sole plate 1002 may be configured such that the protrusions themselves (not shown) act as studs and engage and partially insert into the ground. The sole plate 1002 may include at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 12, at least 15, at least 18, at least 20, at least 25, at least 30, or at least 40 protrusions configured to directly engage the ground without the need for separate studs.

[0135] The soleplate 1002 may be formed from a densified wood panel or panels formed by chemically treating natural wood to remove lignin or hemicellulose or compressing natural wood, as described herein. In some embodiments, the soleplate 1002 may be formed from a composite of densified wood and a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, or a thermoplastic olefin. In some embodiments, the soleplate 1002 may be formed from a composite of densified wood and one or more fibers, such as carbon fiber, aramid fiber, boron fiber, glass fiber, natural fiber, and polymer fiber, or a combination thereof. In these embodiments, the densified wood and / or fibers may be affixed or bonded to a substrate or a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic polyolefin, or a thermoplastic elastomer, by stitching or adhesive. In other embodiments, the soleplate 1002 may be formed from a unidirectional tape including densified wood, carbon fiber, aramid fiber, boron fiber, glass fiber, polymer fiber, or the like. In other embodiments, the soleplate 1002 may be formed from a composite material with at least one layer of densified wood.

[0136] In some embodiments, one or more materials of soleplate 1002 may have a stiffness (e.g., tensile strength) defined by Young's modulus. For example, in certain embodiments, one or more materials forming soleplate 1002 may have a Young's modulus of at least about 25 gigapascals (GPa), at least about 40 GPa, or at least about 70 GPa, or at least about 85 GPa, or at least about 200 GPa. In further embodiments, one or more materials forming plate 170 may have a Young's modulus of about 25 GPa to about 200 GPa, or about 25 GPa to about 80 GPa, or about 25 GPa to about 70 GPa, or about 50 GPa to about 75 GPa.

[0137] In some embodiments, part or all of soleplate 1002 is formed from densified wood having a Young's modulus of about 10 GPa to about 70 GPa, about 12 GPa to about 60 GPa, about 18 GPa to about 58 GPa, about 25 GPa to about 55 GPa, or about 35 GPa to about 50 GPa. In some embodiments, part or all of plate 170 is formed from densified wood having a Young's modulus of at least 10 GPa, at least 12 GPa, at least 15 GPa, at least 20 GPa, at least 25 GPa, at least 30 GPa, at least 40 GPa, at least 50 GPa, or at least 55 GPa.

[0138] In some embodiments, the soleplate 1002 and its stiffness may be selected and designed for a particular user. For example, the stiffness of the soleplate 1002 may be selected based on the user's particular muscle strength, tendon flexibility, or joint flexibility. In further embodiments, the stiffness of the soleplate 1002 may vary, such that one portion of the soleplate 1002 is stiffer compared to another portion of the soleplate 1002. In alternative embodiments, the stiffness of the soleplate 1002 may be uniform and constant.

[0139] In some embodiments, the stiffness of the soleplate 1002 may be altered by increasing or decreasing the number of layers of densified wood therein. In some embodiments, certain areas of the soleplate 1002 may include more layers of densified wood to increase stiffness. In some embodiments, the stiffness of the soleplate 1002 may be altered by combining densified wood with one or more additional materials to achieve a desired stiffness.

[0140] The soleplate 1002 may also include a uniform or substantially uniform thickness of about 0.5 millimeters (mm) to about 3.0 mm, or about 0.5 mm to about 2.0 mm, or about 0.7 mm to about 1.0 mm. In other embodiments, the soleplate 1002 may have a uniform thickness or a thickness that varies across the soleplate 1002.

[0141] Densified wood may also be used in sporting goods structures other than footwear. Some non-limiting examples of structures that may include densified wood include pads, guards, gloves, cleats, cleat studs and spikes, clubs, rackets, bats, drinking bottles, skis and snowboards, ski rods / sticks, protective mobile device covers, watches, helmets, other headgear, skateboards, ice skates, goal posts, javelins, bicycle frames, bicycle pedals / seats, and water sports fins.

[0142] For example, shin guards, such as those worn by soccer / hockey players, may include densified wood. As another example, gloves (particularly reinforced gloves) may include densified wood. In one embodiment, the reinforced gloves have finger support or "finger safety" elements that include densified wood.

[0143] 49 , a front view of the shin guard 1300 is shown, the shin guard 1300 having a front surface 1302, a rear surface 1304, an upper edge 1306, a lower edge 1308, a first side edge 1310, and a second side edge 1312. The front surface 1302 and the rear surface 1304 define the thickness of the shin guard 1300. The upper edge 1306 and the lower edge 1308 define the height of the shin guard 1300. The first side edge 1310 and the second side edge 1312 define the width of the shin guard 1300.

[0144] The front surface 1302 and the rear surface 1304 may define a curve such that the shin guard 1300 has a substantially convex shape. The slope of the curve defined by the front surface 1302 and the rear surface 1304 may vary as the curve moves along the width of the shin guard 1300. Additionally or alternatively, the slope of the curve may vary as the curve moves along the height of the shin guard 1300. In the embodiment shown in FIG. 49 , the slope of the curve defined by the front surface 1302 and the rear surface 1304 is greater near the side edges 1310 and 1312 than near the center of the width of the shin guard 1300. In some embodiments, the curve may have a greater slope near the center of the shin guard. In some embodiments, the curve may be consistent across the length or width of the shin guard.

[0145] Referring again to FIG. 49 , the shin guard 1300 has a greater width near the upper edge 1306 than near the lower edge 1308. Furthermore, the width of the shin guard 1300 approximately halfway between the upper edge 1306 and the lower edge 1308 is less than the width of the shin guard 1300 near the upper edge 1306, but is substantially the same as the width of the shin guard 1300 near the lower edge 1308. In some embodiments, the variation in width of the shin guard may be substantially consistent across the height of the shin guard. In some embodiments, the width near the upper end may be approximately the same as the width near the lower end, or the width of the shin guard may vary across the height of the shin guard. In some embodiments, the width of the shin guard may be substantially consistent along the entire height of the shin guard.

[0146] The shin guard 1300 may have any height and width suitable for use on a human shin. In some embodiments, the height, width, and shape of the shin guard are selected to complement the human shin so that, when worn, the shin guard does not interfere with the natural movement of the human ankle and / or human knee. In some embodiments, the convex curvature of the shin guard defined by the anterior and posterior surfaces may substantially match the curvature of a human shin.

[0147] Referring again to FIG. 49 , the shin guard 1300 has flex grooves 1314 on its front surface 1302. The thickness of the shin guard 1300 is less in the space occupied by the flex grooves 1314 than the entire portion of the shin guard not occupied by the flex grooves 1314. The flex grooves 1314 give the shin guard 1300 the ability to flex more easily. Beneficially, this may allow the shin guard 1300 to better fit the wearer's shin. Additionally, the flex grooves 1314 may allow the shin guard 1300 to elastically deform under tension or compression, which may beneficially allow the shin guard 1300 to better absorb impact, dissipate energy, and / or change shape as needed during use. The flex grooves 1314 may be created by any suitable process. For example, the flex grooves 1314 may be cut into the front surface 1302 after the front surface 1302 is manufactured. Alternatively, the flex grooves 1314 may be formed simultaneously with the rest of the shin guard 1300, for example through a molding process. There may be aesthetic value in having the flex grooves 1314 located on the front surface 1302 of the shin guard 1300, as the flex grooves 1314 are visible during use.

[0148] The shin guard 1300 may include densified wood panels or densified wood panels formed by chemically treating natural wood to remove lignin or hemicellulose or compressing natural wood, as described herein. In some embodiments, the shin guard 1300 may include a composite of densified wood and a thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic elastomer, or a thermoplastic olefin. In some embodiments, the shin guard 1300 may include a composite of densified wood and one or more fibers, such as carbon fiber, aramid fiber, boron fiber, glass fiber, natural fiber, and polymer fiber, or a combination thereof. In these embodiments, the densified wood and / or fibers may be affixed or bonded to a substrate or thermoplastic material, such as a thermoplastic polyurethane, a thermoplastic polyolefin, or a thermoplastic elastomer, by stitching or adhesive. In other embodiments, the shin guard 1300 may include a unidirectional tape including carbon fiber, aramid fiber, boron fiber, glass fiber, polymer fiber, or the like. In other embodiments, the shin guard 1300 may include a composite with at least one layer of densified wood. In some embodiments, the shin guard may have two or more layers, with one or both layers comprising densified wood. In some embodiments, the shin guard may have three or more layers, with one or both layers comprising densified wood. In one embodiment, the shin guard may have two layers, with one layer comprising densified wood and the other layer comprising a material other than densified wood. In another embodiment, the shin guard may have three layers, with one layer comprising densified wood and the other two layers comprising a material other than densified wood. In some embodiments, at least the rear surface 1304 of the shin guard 1300 incorporates aluminum and comprises a material with antibacterial or anti-odor properties. In one embodiment, the densified wood may incorporate aluminum.

[0149] In some embodiments, one or more materials of shin guard 1300 may have a stiffness (e.g., tensile strength) defined by Young's modulus. For example, in certain embodiments, one or more materials (such as densified wood) forming shin guard 1300 may have a Young's modulus of at least about 25 gigapascals (GPa), at least about 40 GPa, or at least about 70 GPa, or at least about 85 GPa, or at least about 200 GPa. In further embodiments, one or more materials forming shin guard 1300 may have a Young's modulus of about 25 GPa to about 200 GPa, or about 25 GPa to about 80 GPa, or about 25 GPa to about 70 GPa, or about 50 GPa to about 75 GPa. In some embodiments, shin guard 1300 is formed in part or entirely from densified wood having a Young's modulus of about 10 GPa to about 70 GPa, about 12 GPa to about 60 GPa, about 18 GPa to about 58 GPa, about 25 GPa to about 55 GPa, or about 35 GPa to about 50 GPa. In some embodiments, shin guard 1300 is formed in part or entirely from densified wood having a Young's modulus of at least 10.0 GPa, at least 12.0 GPa, at least 15.0 GPa, at least 20.0 GPa, at least 25.0 GPa, at least 30.0 GPa, at least 40.0 GPa, at least 50.0 GPa, or at least 55.0 GPa.

[0150] In some embodiments, the stiffness of shin guard 1300 may be altered by increasing or decreasing the number of layers of densified wood therein. In some embodiments, certain areas of shin guard 1300 may include more layers of densified wood to increase stiffness. In some embodiments, the stiffness of shin guard 1300 may be altered by combining densified wood with one or more additional materials to achieve a desired stiffness.

[0151] The shin guard 1300 may also include a uniform or substantially uniform thickness of about 0.5 millimeters (mm) to about 3.0 mm, or about 0.5 mm to about 2.0 mm, or about 0.7 mm to about 1.0 mm. In other embodiments, the shin guard 1300 may have a non-uniform thickness or a thickness that varies across the shin guard 1300. For example, the thickness of the portions of the shin guard 1300 adjacent the first side edge 1310, the second side edge 1312, and the region between these portions (adjacent the center of the width of the shin guard 1300) may be individually selected when the shin guard 1300 is formed. In certain embodiments, the thickness of the shin guard 1300 may be greater near the center of the width of the shin guard 1300 than adjacent the first side edge 1310 or the second side edge 1312.

[0152] Referring now to FIG. 50 , a rear view of the shin guard 1300 previously shown in FIG. 49 is shown. The rear surface 1304 of the shin guard 1300 has substantially the same convex shape, height, and width as the front surface 1302 shown in FIG. 49 . In one embodiment, the rear surface 1304 may comprise the same material as the front surface 1302. In one embodiment, both the rear surface 1304 and the front surface 1302 may comprise densified wood. In an alternative embodiment, the rear surface 1304 may comprise a material different from the material used to fabricate the front surface 1302. In one embodiment, at least the rear surface 1304 comprises densified wood incorporating aluminum and having antibacterial or anti-odor properties. In one embodiment, the rear surface 1304 may comprise a cushioning material such as foam, woven fabric, nonwoven fabric, and / or polymeric material. In one embodiment, the rear surface 1304 may comprise a cushioning material incorporating aluminum and having antibacterial or anti-odor properties. In the embodiment shown in FIG. 50 , there are no flex grooves on the rear surface 1304.

[0153] Referring to FIG. 51 , there is shown a cross-sectional side view of the shin guard 1300 previously shown in FIGS. 49 and 50 . FIG. 51 shows that the shin guard 1300 has two layers: an inner layer 1316 and an outer layer 1318. The inner layer 1316 has an inner surface 1320 and an outer surface 1322. The outer layer 1318 has an inner surface 1324 and an outer surface 1326. The inner surface 1320 of the inner layer 1316 may be the same surface as the rear surface 1304. Alternatively, an additional layer or coating may be disposed on the inner surface 1320 of the inner layer 1316 such that the inner surface 1320 and the rear surface 1304 are different surfaces. Similarly, the outer surface 1326 of the outer layer 1318 may be the same surface as the front surface 1302.

[0154] The outer layer 1318 is in direct contact with the inner layer 1316. In the embodiment shown in FIG. 51 , the inner layer 1316 and the outer layer 1318 are in direct contact with each other along substantially the entire length and width of the shin guard 1300. In an alternative embodiment, the inner and outer layers are in direct contact with each other along a portion of the length of the shin guard, but not along the entire length of the shin guard. In another embodiment, the inner and outer layers are in direct contact with each other along a portion of the width of the shin guard, but not along the entire width of the shin guard.

[0155] The inner layer 1316 and the outer layer 1318 may comprise the same material. Alternatively, the inner layer 1316 and the outer layer 1318 may comprise different materials. In one embodiment, one or both of the inner layer 1316 and the outer layer 1318 comprise densified wood. In some embodiments, the inner layer 1316 and / or the outer layer 1318 comprise a material having a grain or texture. In some embodiments, the inner layer 1316 and / or the outer layer 1318 comprise densified wood having a grain or texture. In FIG. 51 , the grain of the inner layer 1316 and the outer layer 1318 is indicated by a slash mark. In one embodiment, the inner layer 1316 and / or the outer layer 1318 comprise densified wood having a grain or texture, and the inner layer 1316 and the outer layer 1318 are positioned such that their grains / textures are not aligned parallel. In one embodiment, the inner layer 1316 and / or the outer layer 1318 comprises densified wood having a grain or orientation, and the inner layer 1316 and the outer layer 1318 are arranged so that their grains / orientations are aligned perpendicular to one another. In one embodiment, the inner layer 1316 and / or the outer layer 1318 comprises densified wood having a grain or orientation, and the inner layer 1316 and the outer layer 1318 are arranged so that their grains / orientations are aligned at an angle that is neither parallel nor perpendicular to one another. In one embodiment, the inner layer 1316 and / or the outer layer 1318 comprises densified wood having a grain or orientation, and the inner layer 1316 and the outer layer 1318 are arranged so that their grains / orientations are aligned parallel to one another.

[0156] In one embodiment, the shin guard 1300 includes two layers, an inner layer 1316 and an outer layer 1318, where the inner layer 1316 includes a cushioning material such as foam, fabric, or a polymeric material, and the outer layer 1318 includes densified wood. In one embodiment, the shin guard has an inner layer including a cushioning material, an outer layer including densified wood, and one or more additional layers disposed between the inner and outer layers. In one embodiment, the shin guard has an inner layer including a cushioning material, an outer layer including densified wood, and one or more additional layers disposed on either side of the inner and outer layers. It is further contemplated that some embodiments may include a combination of two or more embodiments described herein. In one embodiment, the inner layer 1316 may include a cushioning material incorporating aluminum and / or other materials with antibacterial or anti-odor properties.

[0157] In one embodiment, the shin guard may include only a single layer, and the single layer may include densified wood. The densified wood layer may have any dimensions suitable for use as a shin guard. The densified wood may further be mixed with and / or coated with one or more additives. For example, in one embodiment, the densified wood may have a polymer coating that helps repel fluids or reduces damage to the densified wood. In one embodiment, the densified wood may be enhanced with one or more fillers to tailor its properties to a desired application. It is further contemplated that some embodiments may include a combination of two or more embodiments described herein.

[0158] 52 and 53 show an embodiment of a shin guard 1400 similar to the shin guard 1300 shown in FIGS. 49-51, except that the shin guard 1400 has flex grooves 1414 disposed on its rear surface 1404 and no flex grooves disposed on its front surface 1402. Advantageously, by locating the flex grooves 1414 on the rear surface 1404 rather than the front surface 1402, the front surface 1402 can be made smooth across its entire surface area. This can make the front surface 1402 easier to decorate. This may also make the front surface 1402 more receptive to certain types of additives that may be more difficult to combine with textured surfaces. This can also make the front surface 1402 easier to clean. At the same time, locating the flex grooves 1414 on the rear surface 1404 can provide the shin guard 1400 with substantially the same flexibility and elastic deformation capabilities as the shin guard 1300 described above with reference to FIG. 49. 53, flex grooves 1414 have substantially different dimensions and a substantially different layout than flex grooves 1314. In other embodiments, flex grooves may have any dimensions and any layout suitable for use with a particular embodiment or function.

[0159] In one embodiment, the shin guard of the present disclosure may have flexion grooves disposed on its front and rear surfaces. In an alternative embodiment, the shin guard may not have flexion grooves disposed on either its front or rear surfaces. In one embodiment, at least a portion of the flexion groove may comprise an opening that traverses the depth of the shin guard. In other words, a portion of the flexion groove may form a continuous hole that penetrates each of the front, outer layer, inner layer, and rear surface.

[0160] Those skilled in the art will recognize that embodiments of the present disclosure may form part or all of other types of pads / guards. For example, some embodiments may form part or all of elbow pads, knee pads, wrist pads, ankle pads, helmets, chest pads, and / or thigh pads. Additionally, some embodiments may form a glove or pair of gloves. Certain embodiments may form a glove or pair of gloves with finger support or "finger safety" elements.

[0161] Referring to FIG. 54 , a cross-sectional side view of the shin guard 1400 is shown. FIG. 54 shows that the shin guard 1400 has two layers: an inner layer 1416 and an outer layer 1418. The rear surface 1404 defines the inner limit of the inner layer 1416. The front surface 1402 defines the outer limit of the outer layer 1418. The outer layer 1418 is in direct contact with the inner layer 1416. The layers 1416 and 1418 are similar to the layers 1316 and 1318. The inner layer 1416 and the outer layer 1418 may comprise the same material. Alternatively, the inner layer 1416 and the outer layer 1418 may comprise different materials. In one embodiment, one or both of the inner layer 1416 and the outer layer 1418 comprise densified wood. In some embodiments, the inner layer 1416 and / or the outer layer 1418 may comprise a material having a wood grain or texture. In some embodiments, the inner layer 1416 and / or the outer layer 1418 may comprise densified wood having a grain or texture.

[0162] Any of the embodiments described herein may be modified to include any of the structures or methods disclosed in connection with different embodiments. Similarly, in some embodiments, materials or construction techniques other than those disclosed above may be substituted or added in accordance with known approaches. Furthermore, the present disclosure is not limited to the types of footwear specifically shown. Furthermore, footwear aspects of any of the embodiments disclosed herein may be modified to function with any type of footwear, apparel, or other athletic equipment.

[0163] As previously mentioned, while the present disclosure has been described above with reference to particular embodiments and examples, it will be understood by those skilled in the art that the present disclosure is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications, and departures from the embodiments are intended to be encompassed by the claims appended hereto.

Claims

1. Upper, and a sole structure coupled to the upper and defining a forefoot region, a midfoot region, and a heel region; The sole structure includes: a midsole cushioning member including a top surface and a bottom surface; an opening provided in the midsole cushion member and extending from the top surface to the bottom surface; at least one plate made of densified wood; Including, the plate includes an arch segment, a rear segment, and a toe segment; the toe segment bifurcates into a first toe segment and a second toe segment; The arched segment adjacent the rear segment extends through the opening in the midsole cushioning member.

2. The sole structure comprises: Upper midsole cushioning member, Lower midsole cushioning member, an outsole coupled to a bottom surface of the lower midsole cushioning member; and the plate including densified wood disposed between the upper midsole cushioning member and the lower midsole cushioning member; 10. The footwear of claim 1, comprising:

3. 3. The footwear of claim 2, wherein the plate includes a flat portion and a curved portion including a forward curved portion extending through at least the forefoot region of the footwear, and a rearward curved portion extending through the midfoot region of the footwear and at least a portion of the heel region of the footwear.

4. The article of footwear of claim 2 , wherein the sole structure further includes a heel support structure in the heel region of the article of footwear.

5. 3. The article of footwear of claim 2, wherein the upper midsole cushioning member and the lower midsole cushioning member are foam materials.

6. 4. The footwear according to claim 3, wherein the minimum width of the front curved portion is greater than the minimum width of the rear curved portion, and the minimum width of the flat portion is greater than the minimum width of the rear curved portion.

7. 10. The article of footwear of claim 1, wherein the plate is constructed from a densified wood panel having a density of about 1.4 g / cc to about 1.6 g / cc.

8. 10. The footwear of claim 1, wherein the plate is constructed from a delignified densified wood panel, wherein at least 30% of the lignin has been removed relative to the lignin content of the natural wood prior to delignification.

9. The densified wood is contacting natural wood containing lignin and cellulose with a sodium-based chemical solution for a time and under conditions sufficient to form delignified wood; and 10. The footwear of claim 1, produced by a process comprising compressing the delignified wood until the thickness is reduced by at least 40%.

10. The sodium-based chemical solution is NaOH, NaOH / Na ２ S, NaHSO ３ +SO ２ +H ２ O, NaHSCb, NaHSO ３ +Na ２ SO ３ , NaOH + Na ２ SO ３ , Na ２ SO ３ , NaOH+AQ, NaOH / Na ２ S+AQ, NaHSO ３ +SO ２ +H ２ O+AQ, NaOH+Na ２ SO ３ + AQ, NaHSO ３ + AQ, NaHSO ３ +Na ２ SO ３ + AQ, Na ２ SO ３ +AQ, NaOH+Na ２ S + Na ２ Sn, Na ２ SO ３ + NaOH + CH ３ OH + AQ, C ２ H ５ OH+NaOH, NaClO, NaClO ２ + acetic acid, or a combination thereof, wherein n is an integer, and AQ is an anthraquinone.

11. 10. The footwear of claim 9, wherein the delignified wood is compressed at a pressure of 0.5 MPa to 10 MPa.

12. The delignified wood is about 100 o F ~ approx. 250 o 10. The footwear of claim 9, compressed at F.

13. 10. The footwear of claim 1, wherein the densified wood is made by viscoelastic thermocompression of natural wood.

14. 10. The footwear of claim 1, wherein the plate is constructed from a densified wood panel that has been treated with chemicals to make it hydrophobic, weather-resistant, rot-resistant, or flame-resistant.

15. The article of footwear of claim 1 , wherein the sole structure includes the plate, the plate including one or more protrusions.

16. 16. The article of footwear of claim 15, wherein a stud is attached to each of the one or more protrusions.

17. 17. The article of footwear of claim 16, wherein the studs are formed from metal, rubber, or thermoplastic material.

18. Upper, and a sole structure coupled to the upper, the sole structure defining a forefoot region, a midfoot region, and a heel region; The sole structure includes: a midsole cushioning member including a top surface and a bottom surface; an opening provided in the midsole cushion member and extending from the top surface to the bottom surface; an outsole coupled to the bottom surface of the midsole cushioning member; and a plate; the plate is formed from densified wood and includes a toe portion, an arched portion, and a rear segment; the toe portion bifurcates into a first toe segment and a second toe segment; the toe portion and the arched portion are located between the midsole cushioning member and the outsole, and the rear segment is located above the midsole cushioning member; The arched portion adjacent the rear segment extends through the opening in the midsole cushioning member.

19. Footwear as described in claim 18, wherein the upper comprises densified wood.

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