Sole plate comprising metal plate and methods of making the same

Abstract

Sole plates for an article of footwear, the sole plates comprising a single piece, integrally formed metal plate comprising a top surface, a bottom surface, and a plate thickness measured from the top surface to the bottom surface. The sole plates can comprise a protrusion formed in the metal plate and a corresponding bump on the bottom surface of the metal plate. The protrusion can comprise a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness measured from the cavity surface to the protruding surface. The plate thickness and the wall thickness can be greater than or equal to 0.01 mm and less than or equal to 0.5 mm. The metal plate can be formed by a method comprising stamping, deep drawing, incremental sheet forming, or a combination thereof.

Description

FIELD

[0001] The described embodiments generally relate to articles of footwear and methods of making articles of footwear. In particular, described embodiments relate to sole plates comprising metal plates for use in an article of footwear, and methods of making sole plates comprising metal plates.BACKGROUND

[0002] Footwear can be manufactured from various materials using a wide range of techniques. Individuals are often concerned with the durability, comfort, and / or performance characteristics for an article of footwear. This is true for footwear worn for athletic and non-athletic activities. Footwear worn for athletic activities must meet higher performance standards than footwear for non-athletic activities. For example, many athletic activities require a high degree of agility. This requires footwear that are not heavy or bulky, as heaviness can reduce agility and speed of an athlete. Therefore, a continuing need exists for innovations in footwear and methods of making footwear that reduce the weight of the footwear while providing requisite support.BRIEF SUMMARY

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

[0004] In a second embodiment (2), the cavity according to the first embodiment (1) comprises a maximum depth greater than or equal to 0.5 mm and less than or equal to 22 mm.

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

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

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

[0008] In a sixth embodiment (6), the protrusion according to any one of embodiments (1)-(5) is comprised by a cleat.

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

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

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

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

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

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

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

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

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

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

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

[0020] In an eighteenth embodiment (18), the lateral wing of the seventeenth embodiment (17) is bent in a direction above the top surface of the metal plate and the medial wing of the seventeenth embodiment (17) is bent in a direction above the top surface of the metal plate.

[0021] A nineteenth embodiment (19) of the present application is directed to an article of footwear comprising: an upper; and the sole plate according to any one of embodiments (1)-(18) coupled to the upper.

[0022] A twentieth embodiment (20) of the present application is directed to a method of making a sole plate for an article of footwear, the method comprising: forming a protrusion in a metal plate comprising a top surface, a bottom surface, and a plate thickness, measured from the top surface to the bottom surface, greater than or equal to 0.01 mm and less than or equal to 0.5 mm, wherein the protrusion defines a cavity on the top surface of the metal plate and a bump on the bottom surface of the metal plate, and comprises a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness, measured from the cavity surface to the protruding surface, greater than or equal to 0.01 mm and less than or equal to 0.5 mm, and wherein the forming comprising a process chosen from stamping, deep drawing, and incremental sheet forming.

[0023] In a twenty-first embodiment (21), the method according to the twentieth embodiment (20) further comprises shaping the metal plate while forming the protrusion.

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

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

[0026] In a twenty-fourth embodiment (24), the protrusion according to any one of embodiments (20)-(23) is comprised by a cleat.

[0027] In a twenty-fifth embodiment (25), the method according to any one of embodiments (20)-(24) further comprises forming a variable plate thickness in the metal plate, the forming the variable plate thickness comprising selectively thinning a region of the metal plate adjacent a region selected to form the protrusion.BRIEF DESCRIPTION OF THE FIGURES

[0028] FIG. 1 shows a sole plate comprising a metal plate according to some embodiments.

[0029] FIG. 2 shows a section view of the sole plate of FIG. 1, taken along line 2′-2′, according to some embodiments.

[0030] FIG. 3 shows a section view of the sole plate of FIG. 1, taken along line 3′-3′, according to some embodiments.

[0031] FIG. 4 shows a section view of the sole plate of FIG. 1, taken along line 4′-4′, according to some embodiments.

[0032] FIG. 5 shows the sole plate of FIG. 1, according to some embodiments.

[0033] FIG. 6 shows a section view of the sole plate of FIG. 5, taken along line 6′-6′, according to some embodiments.

[0034] FIG. 7 shows the sole plate of FIG. 1, according to some embodiments.

[0035] FIG. 8 shows a section view of the sole plate of FIG. 7, taken along line 8′-8′, according to some embodiments.

[0036] FIG. 9 shows an article of footwear, according to some embodiments.

[0037] FIG. 10 shows an article of footwear, according to some embodiments.

[0038] FIGS. 11A-11B show sole plates, according to some embodiments.

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

[0040] FIGS. 13A-13C show a mold for forming a metal plate, according to some embodiments.

[0041] FIG. 14 shows a sheet comprising metal plates, according to some embodiments.

[0042] FIG. 15 shows various surface configurations for a metal plate, according to some embodiments.

[0043] FIG. 16 shows a metal plate comprising different surface configurations and / or orientations thereof in different regions, according to some embodiments.

[0044] FIGS. 17A-17B show sole plates comprising metal plates and polymer segments, according to some embodiments.

[0045] FIG. 18 shows various configurations for coupling a polymer segment to a metal plate, according to some embodiments.

[0046] FIGS. 19A-19C show protrusions comprising polymer segments according to some embodiments.

[0047] FIG. 20 shows a sole plate comprising a secondary metal plate, according to some embodiments.

[0048] FIG. 21 shows a section view of the sole plate of FIG. 20, taken along line 21′-21′, according to some embodiments.

[0049] FIG. 22 shows a section view of the sole plate of FIG. 20, taken along line 22′-22′, according to some embodiments.

[0050] FIG. 23 shows a sole plate comprising metal plates and metal segments, according to some embodiments.

[0051] FIG. 24 shows a section view of the sole plate of FIG. 23, taken along line 24′-24′, according to some embodiments.

[0052] FIG. 25 shows metal segments coupling metal plates, according to some embodiments.

[0053] FIG. 26 shows a draping simulation according to some embodiments.

[0054] FIGS. 27A-27B show a metal sheet formed based on the draping simulation of FIG. 26, according to some embodiments.

[0055] FIG. 28 is an exemplary flowchart of a method, according to some embodiments.DETAILED DESCRIPTION

[0056] The present invention(s) will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings. References to “some embodiments”, “one embodiment”, “an embodiment”, “an exemplary embodiment”, etc., indicate that the embodiment described can comprise a particular feature, structure, or characteristic, but every embodiment may not necessarily comprise the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0057] The indefinite articles “a,”“an,” and “the” include plural referents unless clearly contradicted or the context clearly dictates otherwise.

[0058] The term “comprising” is an open-ended transitional phrase. A list of elements following the transitional phrase “comprising” is a non-exclusive list, such that elements in addition to those specifically recited in the list can also be present.

[0059] As used herein, unless specified otherwise, references to “first,”“second,”“third,”“fourth,” etc. are not intended to denote order, or that an earlier-numbered feature is required for a later-numbered feature. Also, unless specified otherwise, the use of “first,”“second,”“third,”“fourth,” etc. does not necessarily mean that the “first,”“second,”“third,”“fourth,” etc. features have different properties or values.

[0060] As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination, unless it is evident from the context that a particular single listed item by itself or combination is impossible.

[0061] An article of footwear has many purposes. Among other things, footwear can provide a unique aesthetic look, provide warming or cooling characteristics, provide support for portions of an individual's foot or ankle, and provide other performance characteristics, such as air permeability, moisture wicking properties, compression properties, energy return properties, and weight properties. Each of these purposes, alone or in combination, provides for footwear suitable for use in athletic competition. The features of an article of footwear (for example, the materials and components used to make footwear, and the way these materials / components are made) can be altered to produce desired characteristics, for example, durability, stiffness, weight, tackiness, texture, haptics, and / or air permeability.

[0062] An important consideration in athletic footwear is weight. For each ounce added to an article of athletic footwear, an athlete must exert more energy to lift and move the article of footwear. This can be a drain on an athlete's energy, which is better put to use executing desired athletic movements such as sprinting, cutting, or kicking a ball. The ability to produce light components for an article of footwear can improve the speed, agility, and dexterity of an athlete. Simultaneously, the components must maintain a certain level of stiffness necessary for providing durability, energy return, and / or support, depending on the component. However, as long as a requisite level of stiffness is met for a certain component, making the component lighter is usually beneficial.

[0063] In some cases, certain materials and manufacturing processes limit the extent to which light components can be manufactured, for example, by limiting how thin the components can be. Often, a sole plate for an article of footwear is made from polyamide (nylon) or another thermoplastic polymer using injection molding. When injection molding a thermoplastic polymer such as nylon, it is difficult to obtain a component with a thickness less than about 0.9 mm, for example. This is because it can be difficult to cause the thermoplastic polymer to flow throughout portions of a mold that are spaced less than about 0.9 mm apart. Accordingly, there is a limit to how thin, and therefore how light, a sole plate or other component made from a thermoplastic polymer can be. Additional problems exist, including that a plastic component under a certain thickness can be prone to cracking, breaking, or stretching during athletic competition.

[0064] To address these problems, and according to embodiments of the present disclosure, a metal material can be used with a manufacturing process comprising stamping, deep drawing, incremental sheet forming (ISF) (for example, single point ISF), and / or another sheet metal forming process. Metal components (for example, for sole plates) as described herein can be lighter than a polymer component while performing the same function, and in some cases improving on that function. At least the following features of various metals, as compared to thermoplastic polymers, enable the manufacturing of functional metal plates for sole plates according to embodiments of the present disclosure that are lighter than comparable polymer sole plates.

[0065] The density of steel (about 7.85 grams per cubic centimeter (g / cc)) is approximately 8 times that of nylon (about 1.01 g / cc). The density of titanium (about 4.5 g / cc) is approximately 4.5 times that of nylon. Accordingly, in order to be lighter than a theoretical nylon sole plate with an unvarying thickness, a steel sole plate would need to be more than 8 times thinner, on average, than the nylon sole plate. A titanium sole plate would need to be more than 4.5 times thinner, on average. Using manufacturing processes such as stamping, deep drawing, and / or ISF, metals such as steel and titanium can be formed into functional components having a thickness as small as 0.01 mm. Accordingly, a steel sole plate that is 0.1 mm thick on average can be formed and is 9 times thinner on average, and therefore lighter, than a nylon sole plate with a thickness of 0.9 mm, likely the smallest practical thickness for nylon. Likewise, a titanium sole plate that is 0.15 mm thick on average can be formed and is 6 times thinner on average, and therefore even more significantly lighter, than a nylon sole plate with a thickness of 0.9 mm.

[0066] These weight reductions are magnified by the following factors, either alone or in combination:

[0067] 1. A nylon or other thermoplastic polymer sole plate of unvarying 0.9 mm thickness represents a theoretical bottom limit for thickness and weight. In practice, nylon or other thermoplastic polymer sole plates will have portions that are thicker than 0.9 mm, thereby increasing weight as compared to sole plates described herein.

[0068] 2. Often nylon or other thermoplastic polymer sole plates comprise solid thermoplastic polyurethane (TPU) cleat components. TPU's density is higher than that of nylon, thereby increasing weight as compared to sole plates described herein.

[0069] 3. Structural features on typical nylon or other thermoplastic polymer sole plates are often solid to provide requisite rigidity. In contrast, a metal plate can be formed, using stamping, deep drawing, and / or incremental sheet forming, to comprise structural features (for example, cleats or ridges) that are hollow yet still rigid and supportive.

[0070] The sole plates described herein can comprise a single piece, integrally formed metal plate comprising a top surface configured to face other component(s) of an article of footwear, a bottom surface configured to face and / or interact with a ground surface, and a plate thickness measured from the top surface to the bottom surface. In some embodiments, the metal plate can be configured to span substantially all of the area of a sole of an article of footwear. The construction, dimensions, and methods of manufacturing sole plates according to embodiments of the present disclosure fully or partially overcome the above-noted problems.

[0071] FIG. 1 shows a sole plate 100 according to some embodiments. In some embodiments, sole plate 100 can be configured for a particular side of a pair of footwear. For example, FIG. 1 shows a sole plate 100 configured for a left-footed article of footwear. However, a sole plate 100 can be configured for a right-footed article of footwear and can comprise the same features, in mirror image, as those described for sole plate 100 shown in FIG. 1.

[0072] Sole plate 100 comprises a metal plate 101. In some embodiments, sole plate 100 can comprise additional components to metal plate 101, such as polymer components coupled to metal plate 101. In some embodiments, sole plate 100 can comprise only metal plate 101 and other metal elements integrally formed with metal plate 101.

[0073] In some embodiments, metal plate 101 can be a single piece, integrally formed plate. That is, no component of metal plate 101 is formed and subsequently coupled to any other component of metal plate 101 except a surface finish that would be included in the thickness of metal plate 101, as described herein. In some embodiments, metal plate 101 can comprise a steel (for example, a maraging steel), titanium, a titanium alloy, aluminum, an aluminum alloy, brass, INCONEL®, nitinol, WASPALOY®, and / or similar lightweight metal.

[0074] In some embodiments, metal plate 101 can comprise a metal having a density greater than or equal to 4 g / cc and less than or equal to 8 g / cc. More specifically, in some embodiments, metal plate 101 can comprise a metal having a density greater than or equal to 4 g / cc and less than or equal to 7 g / cc, greater than or equal to 4 g / cc and less than or equal to 6 g / cc, greater than or equal to 4 g / cc and less than or equal to 5 g / cc, greater than or equal to 5 g / cc and less than or equal to 8 g / cc, greater than or equal to 6 g / cc and less than or equal to 8 g / cc, or greater than or equal to 7 g / cc and less than or equal to 8 g / cc.

[0075] In some embodiments, metal plate 101 can be sized to extend from a forefoot end (for example, forefoot end 902 shown in FIG. 9) to a heel end (for example, heel end 904) of an article of footwear (for example, article of footwear 900) of which it forms a part. Additionally or alternatively, in some embodiments, metal plate 101 can be sized to extend from a lateral side (for example, lateral side 910) to a medial side of an article of footwear (for example, article of footwear 900) of which it forms a part. In some embodiments, metal plate 101 can be sized to extend from the lateral side to the medial side of the article of footwear along the entire length of the article of footwear.

[0076] In some embodiments, metal plate 101 can be sized to span greater than 50 percent of the area of a sole of the article of footwear. More specifically, metal plate 101 can be sized to span greater than 60 percent, greater than 70 percent, greater than 80 percent, greater than 90 percent, greater than 95 percent, or all of the area of a sole of the article of footwear.

[0077] In some embodiments, metal plate 101 can comprise a mass greater than or equal to 30 grams and less than or equal to 80 grams. More specifically, in some embodiments, metal plate 101 can comprise a mass greater than or equal to 30 grams and less than or equal to 70 grams, greater than or equal to 30 grams and less than or equal to 60 grams, greater than or equal to 30 grams and less than or equal to 50 grams, or greater than or equal to 30 grams and less than or equal to 40 grams.

[0078] Metal plate 101 can comprise a top surface 102. Top surface 102 can be configured to face and be coupled to other component(s) of an article of footwear, for example, a midsole and upper. As used herein, two components described as coupled to each other means the first component and second component are coupled to each other either directly or indirectly via another component, adhesive, etc., unless otherwise designated as being either directly or indirectly coupled.

[0079] Metal plate 101 can comprise a bottom surface 104. Bottom surface 104 can be configured to face and / or interact with a ground surface, for example, a field, artificial turf, a track, dirt, mud, etc.

[0080] Metal plate 101 can comprise a perimeter edge 105 where top surface 102 transitions into bottom surface 104.

[0081] Sole plate 100 can comprise one or more protrusions 106. In some embodiments, the protrusions 106 can be formed in metal plate 101 by stamping, deep drawing, and / or ISF. Accordingly, in some embodiments, metal plate 101 can comprise the one or more protrusions 106.

[0082] Protrusions 106 can comprise multiple types of protrusions. For example, protrusions 106 can comprise one or more cleats 106a and / or one or more ridges 106b. In some embodiments, cleats 106a can be configured to interact with a ground surface to provide traction with the ground surface. In some embodiments, ridges 106b can be configured to provide additional stiffness and / or flexibility to metal plate 101, depending on their orientation. However, ridges 106b can also be configured to interact with a ground surface to provide traction with the ground surface, for example, if the ground surface is soft (for example, muddy).

[0083] As shown in FIG. 1, metal plate 101 can comprise a lateral side 110. Lateral side 110 can be configured to face toward an outside of a wearer's foot in an as-worn position. For example, if an article of footwear comprising metal plate 101 is a left-footed article of footwear, lateral side 110 would face to the left of a wearer.

[0084] Likewise, metal plate 101 can comprise a medial side 120. Medial side 120 can be configured to face toward an inside of the wearer's foot in an as-worn position. For example, if an article of footwear comprising metal plate 101 is a left-footed article of footwear, medial side 120 would face toward the space between the wearer's feet and toward the right of the wearer.

[0085] In some embodiments, metal plate 101 can comprise a forefoot portion 130. In such embodiments, forefoot portion 130 can be the portion of metal plate 101 configured to occupy a front half of an article of footwear (for example, article of footwear 900 shown in FIG. 9) comprising metal plate 101. The front half of the article of footwear comprises portions of the article of footwear that are closer than 50 percent of the length of the article of footwear from its extreme forefoot tip.

[0086] In some embodiments, metal plate 101 can comprise a rearfoot portion 140. In such embodiments, rearfoot portion 140 can be the portion of metal plate 101 configured to occupy a rear half of an article of footwear (for example, article of footwear 900 shown in FIG. 9) comprising metal plate 101. The rear half of the article of footwear comprises portions of the article of footwear that are farther than 50 percent of the length of the article of footwear from its extreme forefoot tip.

[0087] Forefoot portion 130 and rearfoot portion 140 need not occupy the entireties of the front and rear half of an article of footwear, respectively.

[0088] Metal plate 101 can have a longitudinal axis LP extending along the longest dimension of metal plate 101. When metal plate 101 is viewed face-on from either its top surface 102 side or bottom surface 104 side, longitudinal axis LP is a straight line extending between the two points on perimeter edge 105 that are farthest apart, as shown in FIG. 5. However, longitudinal axis LP can follow the general curvature (excepting protrusions 106) of metal plate 101 in a vertical direction V as shown in FIG. 1.

[0089] FIG. 1 shows cleats 106a having generally circular horizontal cross-sections. In some embodiments, this can result from a stamping, deep drawing, or ISF process, though deep drawing can naturally result in such circular horizontal cross-sections. However, in some embodiments, cleats 106a need not have generally circular horizontal cross-sections. For example, cleats 106a can be irregularly shaped as shown in FIG. 5. Additionally, cleats 106a can define flat bumps, as shown in FIG. 1, or pointed, rounded, and / or textured bumps.

[0090] Likewise, ridges 106b can have different shapes than those shown in FIG. 1. For example, a ridge 106b can define a rounded bump, as shown in FIG. 3, a flat bump, as shown in FIG. 4, or a pointed bump. The shapes shown in FIGS. 1, 3, and 4 should not be construed to limit the shape of ridges 106b. As used herein, the term “ridge” refers to a protrusion 106 that has a length, as measured parallel to surrounding portions of bottom surface 104, more than two times its maximum width, as defined with respect to FIG. 3. In some embodiments, a ridge 106b can adjoin a cleat 106a.

[0091] While FIG. 1 shows metal plate 101 comprising 20 cleats 106a and four ridges 106b, metal plate 101 can comprise any number of cleats 106a and any number of ridges 106b, arranged in any configuration. In some embodiments, metal plate 101 can comprise no cleats 106a. In some embodiments, metal plate 101 can comprise no ridges 106b.

[0092] Additionally, while FIG. 1 shows metal plate 101 comprising a solid structure with no voids, in some embodiments, slits, holes, and / or other voids can be formed in metal plate 101.

[0093] FIG. 2 shows a cross-section of metal plate 101 shown in FIG. 1, taken along line 2′-2′ and viewed from the forefoot end of metal plate 101, according to some embodiments.

[0094] As shown in FIG. 2, metal plate 101 comprises a plate thickness tP measured from top surface 102 to bottom surface 104. The measurement of plate thickness tP can apply to portions of metal plate 101 comprising protrusions 106. In some embodiments, plate thickness tP can be greater than or equal to 0.01 mm and less than or equal to 0.5 mm. More specifically, plate thickness tP can be greater than or equal to 0.01 mm and less than or equal to 0.4 mm, greater than or equal to 0.01 mm and less than or equal to 0.35 mm, greater than or equal to 0.01 mm and less than or equal to 0.3 mm, greater than or equal to 0.01 mm and less than or equal to 0.25 mm, greater than or equal to 0.01 mm and less than or equal to 0.20 mm, greater than or equal to 0.01 mm and less than or equal to 0.15 mm, or greater than or equal to 0.01 mm and less than or equal to 0.1 mm. Metal plates 101 having plate thicknesses tP in such ranges can comprise average thicknesses that remain below upper limits for the metal plates 101 being lighter than corresponding polymer sole components. In some embodiments, metal plate 101 can comprise a minimum plate thickness greater than or equal to 0.01 mm and less than or equal to 0.15 mm, for example, greater than or equal to 0.01 mm and less than or equal to 0.12 mm, greater than or equal to 0.01 mm and less than or equal to 0.10 mm, greater than or equal to 0.01 mm and less than or equal to 0.8 mm, or greater than or equal to 0.01 mm and less than or equal to 0.5 mm.

[0095] In some embodiments, a deviation of plate thickness tP can be ±300 microns. More specifically, a deviation of plate thickness tP can be ±250 microns, ±225 microns, ±200 microns, ±175 microns, ±150 microns, ±125 microns, ±100 microns, ±75 microns, ±50 microns, ±25 microns, ±10 microns, or ±5 microns. A deviation of plate thickness tP being ±5 microns, for example, means that metal plate 101 at its greatest thickness is not more than 5 microns thicker than at its mean thickness, and at its least thickness is not more than 5 microns thinner than at its mean thickness, the mean thickness being calculated as the average of the greatest and least thicknesses. It should be noted that a fold in metal plate 101 causing metal plate 101 to form two layers locally is not considered a change in plate thickness tP. Plate thickness tP at the fold is the thickness of a single layer of the fold.

[0096] In some embodiments, a deviation of plate thickness tP can be any of the above values across at least a minimum area percentage of metal plate 101. In some embodiments, a deviation of plate thickness tP can be any of the above values across 30% or more of the area of metal plate 101. More specifically, a deviation of plate thickness tP can be any of the above values across 40% or more, across 50% or more, across 60% or more, across 70% or more, across 80% or more, across 90% or more, or across 95% or more of the area of metal plate 101. In this context, the area of metal plate 101 can be approximated by determining the volume of metal plate 101 using a submersion method, factoring in its density (for example, based on metal type) to determine its total surface area, and dividing this value by 2.

[0097] In some embodiments, a deviation of plate thickness tP can be any of the above values across any of the above percentages ranges for area, excluding the wall thicknesses and the area of protrusions 106 in the calculation. Excluding the area of protrusions 106 can comprise subtracting the surface area of their protruding surfaces from the above approximation.

[0098] In some embodiments, a deviation of plate thickness tP can be any of the above values across particular regions, either including or excluding wall thicknesses of protrusions 106 in the calculation. For example, in some embodiments, a deviation of plate thickness tP can be any of the above values across forefoot portion 130, either including or excluding protrusions 106 in forefoot portion 130. In some embodiments, a deviation of plate thickness tP can be any of the above values across rearfoot portion 140, either including or excluding protrusions 106 in rearfoot portion 140. In some embodiments, a deviation of plate thickness tP can be any of the above values across a region 150, an example of which is shown in FIG. 1, that encompasses two protrusions 106, either including or excluding the two protrusions 106. In some embodiments, a deviation of plate thickness tP can be any of the above values across a region 150 that encompasses a group of protrusions 106, for example three protrusions 106, four protrusions 106, all the protrusions 106 in the forefoot portion 130, or all the protrusions 106 in the rearfoot portion 140, either including or excluding the group of protrusions 106.

[0099] In some embodiments, metal plate 101 can be configured to have a variable plate thickness tP. For example, in some embodiments, metal plate 101 can be formed before the formation of protrusions 106 to have regions comprising smaller thicknesses and regions comprising greater thicknesses. In such embodiments, the formation of metal plate 101 to have variable thickness can comprise roller milling, stamping, laser ablation, or forging a metal plate having variable thickness.

[0100] In some embodiments, rearfoot portion 140 of metal plate 101 can comprise a greater plate thickness as compared to forefoot portion 130. This can provide increased stiffness in rearfoot portion 140, particularly near the heel. In some embodiments, rearfoot portion 140 can comprise a plate thickness that is at least 0.1 mm greater than a plate thickness comprised by forefoot portion 130. More specifically, in some embodiments, rearfoot portion 140 can comprise a plate thickness that is at least 0.2 mm, at least 0.3 mm, at least 0.4 mm, or at least 0.5 mm greater than a plate thickness comprised by forefoot portion 130.

[0101] In some embodiments, portions of rearfoot portion 140 not comprising protrusions 106 can comprise a plate thickness greater than or equal to 0.3 mm and less than or equal to 0.5 mm and portions of forefoot portion 130 not comprising protrusions 106 can comprise a plate thickness greater than or equal to 0.01 mm and less than or equal to 0.3 mm. In some embodiments, portions of rearfoot portion 140 not comprising protrusions 106 can comprise a plate thickness greater than or equal to 0.2 mm and less than or equal to 0.5 mm and portions of forefoot portion 130 not comprising protrusions 106 can comprise a plate thickness greater than or equal to 0.01 mm and less than or equal to 0.2 mm. In some embodiments, portions of rearfoot portion 140 not comprising protrusions 106 can comprise a plate thickness greater than or equal to 0.4 mm and less than or equal to 0.5 mm and portions of forefoot portion 130 not comprising protrusions 106 can comprise a plate thickness greater than or equal to 0.01 mm and less than or equal to 0.4 mm.

[0102] In some embodiments, forefoot portion 130 of metal plate 101 can comprise a greater plate thickness as compared to rearfoot portion 140. In some embodiments, forefoot portion 130 can comprise a plate thickness that is at least 0.1 mm greater than a plate thickness comprised by rearfoot portion 140. More specifically, in some embodiments, forefoot portion 130 can comprise a plate thickness that is at least 0.2 mm, at least 0.3 mm, at least 0.4 mm, or at least 0.5 mm greater than a plate thickness comprised by rearfoot portion 140.

[0103] In some embodiments, a surface finish can be applied to metal plate 101. In some embodiments, the surface finish can be applied by an electrochemical process, for example, electroplating, anodizing, electroless plating, etc. In some embodiments, the surface finish can be applied by a chemical conversion coating process, for example, a black oxide conversion coating, phosphate conversion coating, etc. In some embodiments, the surface finish can be applied by a mechanical coating process, for example, peening, mechanical plating, etc. In some embodiments, the surface finish can be applied by thermal spraying, vapor deposition, galvanization, cladding and laminating, enameling, etc. In some embodiments, the surface finish can be applied by a dip coating process, for example, in liquid TPU. In some embodiments, the surface finish can comprise paint and / or organic coatings, for example, liquid paint applied and subsequently dried, a powder coating, polymer coating, ceramic coating, etc.

[0104] For any thicknesses and deviations thereof disclosed herein (for example, of metal plate 101 or a protrusion 106), in embodiments of metal plate 101 that comprise a surface finish, the thicknesses and deviations are measured with a surface finish included. That is, for a metal plate 101 to which a surface finish has been applied, top surface 102 and bottom surface 104 are considered to include the surface finish, unless the surface finish is a readily distinguishable material (e.g., TPU or paint) that can be removed in a manner in which the boundary between the material and metal plate 101 is clearly visible to the naked eye.

[0105] FIG. 2 shows a cross-section of two protrusions 106 formed in metal plate 101. Protrusions 106 shown in FIG. 2 are cleats 106a; however, the disclosure related to FIG. 2 can apply to any protrusion 106, unless it is specifically noted that a feature belongs to a cleat 106a.

[0106] A protrusion 106 can define a cavity 210 on top surface 102. Cavity 210 can have a top perimeter 230 where top surface 102 begins to transition into cavity 210. Accordingly, top perimeter 230 can be defined by an edge 232 on top surface 102 where top surface 102 transitions into cavity 210. In some embodiments, edge 232 can be rounded. In such embodiments, edge 232 can comprise a radius of curvature rE. In some embodiments, radius of curvature rE can be greater than or equal to 0.1 mm and less than or equal to 5 mm. More specifically, radius of curvature rE can be greater than or equal to 0.1 mm and less than or equal to 3 mm, greater than or equal to 0.1 mm and less than or equal to 1.5 mm, greater than or equal to 0.1 mm and less than or equal to 1 mm, greater than or equal to 0.1 mm and less than or equal to 0.5 mm, or greater than or equal to 0.1 mm and less than or equal to 0.3 mm.

[0107] A protrusion 106 can define a bump 220 on bottom surface 104 in a location corresponding to cavity 210 on top surface 102.

[0108] A protrusion 106 can comprise a cavity surface 212 defined by top surface 102 of metal plate 101 in the area of the protrusion 106. Similarly, a protrusion 106 can comprise a protruding surface 222 defined by bottom surface 104 of metal plate 101 in the area of the protrusion 106. A protrusion 106 can comprise a wall thickness tW measured from cavity surface 212 to protruding surface 222.

[0109] A protrusion 106 forms a part of metal plate 101. Accordingly, wall thickness tW can be any of the values described above for plate thickness tP. Additionally, a deviation of wall thickness tW can be any of the values described above for the deviation of plate thickness tP, either across all of a protrusion 106 or across at least a minimum area percentage of the protrusion 106 as described above for metal plate 101. In this context, the area of a protrusion is the surface area of its protruding surface 222.

[0110] In some embodiments, a wall thickness tW of a protrusion 106 can be less than plate thickness tP, either globally or in a region adjacent the protrusion 106. In some embodiments, this can result from a stamping, deep drawing, or ISF process, which can thin metal plate 101 as metal plate 101 is stretched to form the protrusion 106. In some embodiments, for example, an ISF embodiment, a wall thickness tW of a protrusion 106 can be up to 50% less than plate thickness tP in a region adjacent the protrusion 106. In some embodiments, for example, a stamping embodiment, a wall thickness tW of a protrusion 106 can be up to 40% less than plate thickness tP in a region adjacent the protrusion 106

[0111] In some embodiments, a wall thickness tW of a protrusion 106 can be substantially equal to (for example, less than or equal to a 10% difference) plate thickness tP, either globally or in a region adjacent the protrusion 106. In some embodiments, this can be accomplished by selectively thinning metal plate 101 in regions other than, for example, regions adjacent to, those selected to form one or more protrusions 106, before the one or more protrusions 106 are formed. In such embodiments, the thinning of metal plate 101 during the formation of the one or more protrusions 106 can then approximately even the thicknesses in the regions. An example region 160 adjacent to a region selected to form a protrusion 106 is shown in FIG. 1.

[0112] A cavity 210 of a protrusion 106 can comprise a maximum depth dMAX, measured, in a direction perpendicular to a plane P defined by top perimeter 230 of the cavity 210, from a point on plane P to a point on cavity surface 212. For any protrusion 106, in some embodiments, dMAX can be greater than or equal to 0.5 mm and less than or equal to 22 mm. More specifically, in some embodiments, dMAX can be greater than or equal to 2 mm and less than or equal to 15 mm, greater than or equal to 5 mm and less than or equal to 12 mm, or greater than or equal to 7 mm and less than or equal to 10 mm.

[0113] For a cleat 106a specifically, in some embodiments, dMAX can be greater than or equal to 5 mm and less than or equal to 22 mm. More specifically, in some embodiments, dMAX can be greater than or equal to 7 mm and less than or equal to 15 mm, greater than or equal to 10 mm and less than or equal to 15 mm, or greater than or equal to 12 mm and less than or equal to 15 mm for a cleat 106a. In some embodiments, dMAX can be greater than or equal to 12 mm and less than or equal to 21 mm, greater than or equal to 15 mm and less than or equal to 21 mm, or greater than or equal to 18 mm and less than or equal to 21 mm for a cleat 106a.

[0114] As shown in FIG. 2, a cavity 210 can define a draw angle Θ. Draw angle Θ is measured as an angle between a sidewall portion 214 of cavity surface 212 and a line l extending perpendicularly to plane P into the cavity 210. In some embodiments, draw angle Θ can be substantially constant over an entire sidewall portion 214 (i.e., the sidewall portion 214 is substantially linear along the vertical cross-section shown in FIG. 2). In some embodiments, draw angle Θ can vary along a sidewall portion 214, for example, by over ±10 degrees, over ±20 degrees, or over ±30 degrees. In some embodiments, a sidewall portion 214 can be convex, or bowed inward into cavity 210. In some embodiments, a sidewall portion 214 can be concave.

[0115] For any protrusion 106, in some embodiments, draw angle Θ can be greater than or equal to 0 degrees and less than or equal to 20 degrees. More specifically, in some embodiments, draw angle Θ can be greater than or equal to 0 degrees and less than or equal to 15 degrees, greater than or equal to 0 degrees and less than or equal to 10 degrees, greater than or equal to 0 degrees and less than or equal to 7 degrees, greater than or equal to 0 degrees and less than or equal to 5 degrees, or greater than or equal to 0 degrees and less than or equal to 2 degrees.

[0116] FIG. 2 shows two protrusions 106. But in addition to a protrusion 106 of a particular type, in some embodiments, sole plate 100 can comprise additional protrusions 106 of the particular type. For example, in some embodiments, sole plate 100 can comprise a cleat 106a and a plurality of additional cleats 106a, as shown in FIG. 1. Likewise, in some embodiments, sole plate 100 can comprise a ridge 106b and a plurality of additional ridges 106b, as shown in FIG. 1. In some embodiments, the plurality of additional ridges 106b can be part of a series of corrugated ridges, as described with respect to FIG. 4. The plurality of additional protrusions 106 of the particular type can comprise the same or similar features to the protrusion or protrusions 106 of the corresponding type described herein.

[0117] As shown in FIG. 2, top surface 102 of metal plate 101 can comprise a perimeter area 240. In some embodiments, perimeter area 240 can comprise a concave curvature. This concave curvature may facilitate attachment to a bottom of an article of footwear and / or provide a smooth transition between metal plate 101 and remaining portions of the article of footwear. In some embodiments, particular portions of top surface 102 can comprise a concave region. For example, in some embodiments, top surface 102 in rearfoot portion 140 of metal plate 101 can comprise a concave region to accommodate a heel of a wearer. Alternatively or additionally, in some embodiments, top surface 102 in forefoot portion 130 of metal plate 101 can comprise a concave region to accommodate a forefoot of a wearer.

[0118] FIG. 3 shows a cross-section of metal plate 101 shown in FIG. 1, taken along line 3′-3′ and viewed from the forefoot end of metal plate 101, according to some embodiments. In particular, FIG. 3 shows a cross-section of two protrusions 106 formed in metal plate 101 according to some embodiments. Protrusions 106 shown in FIG. 3 are ridges 106b; however, the disclosure related to FIG. 3 can apply to any protrusion 106, unless it is specifically noted that a feature belongs to a ridge 106b.

[0119] A protrusion 106 can comprise a lengthwise axis LR, shown extending into the page in FIG. 3. Lengthwise axis LR runs along the longest dimension of the protrusion 106. As shown in FIG. 3, a protrusion 106 can comprise a maximum width wMAX. wMAX is measured perpendicular to lengthwise axis LR of a protrusion 106 between edges 302 of bump 220 defined by the protrusion 106 on bottom surface 104. In some embodiments, edges 302 of the bump 220 can be defined by points where bottom surface 104 transitions from portions adjacent the protrusion 106 into bump 220 and protruding surface 222, that is, where bottom surface 104 begins to curve into bump 220 defined by the protrusion 106.

[0120] For any protrusion 106, in some embodiments, wMAX can be greater than or equal to 1 mm and less than or equal to 30 mm. More specifically, in some embodiments, wMAX can be greater than or equal to 3 mm and less than or equal to 20 mm, greater than or equal to 5 mm and less than or equal to 20 mm, greater than or equal to 10 mm and less than or equal to 20 mm, or greater than or equal to 10 mm and less than or equal to 15 mm.

[0121] For a ridge 106b specifically, in some embodiments, wMAX can be greater than or equal to 0.5 mm and less than or equal to 10 mm. More specifically, in some embodiments, wMAX can be greater than or equal to 0.5 mm and less than or equal to 8 mm, greater than or equal to 0.5 mm and less than or equal to 6 mm, greater than or equal to 0.5 mm and less than or equal to 4 mm, greater than or equal to 0.5 mm and less than or equal to 2.5 mm, or greater than or equal to 0.5 mm and less than or equal to 1 mm for a ridge 106b.

[0122] For a ridge 106b specifically, in some embodiments, dMAX can be greater than or equal to 0.5 mm and less than or equal to 15 mm. More specifically, in some embodiments, dMAX can be greater than or equal to 0.5 mm and less than or equal to 12 mm, greater than or equal to 0.5 mm and less than or equal to 10 mm, greater than or equal to 0.5 mm and less than or equal to 7 mm, greater than or equal to 0.5 mm and less than or equal to 5 mm, or greater than or equal to 0.5 mm and less than or equal to 2 mm for a ridge 106b.

[0123] For a ridge 106b specifically, in some embodiments, a ratio of the maximum depth dMAX of the ridge 106b to the maximum width wMAX of the ridge 106b can be greater than or equal to 1:10 and less than or equal to 10:1. More specifically, in some embodiments, the ratio can be greater than or equal to 1:2 and less than or equal to 10:1, greater than or equal to 1:1 and less than or equal to 10:1, greater than or equal to 2:1 and less than or equal to 10:1, greater than or equal to 5:1 and less than or equal to 10:1, greater than or equal to 1:10 and less than or equal to 2:1, greater than or equal to 1:10 and less than or equal to 1:1, greater than or equal to 1:10 and less than or equal to 1:2, greater than or equal to 1:10 and less than or equal to 1:5, greater than or equal to 1:5 and less than or equal to 5:1, greater than or equal to 1:2 and less than or equal to 2:1, or about 1:1 for a ridge 106b.

[0124] FIG. 3 shows two ridges 106b. But in addition to a ridge 106b shown in FIG. 3, in some embodiments, sole plate 100 can comprise additional ridges 106b. In some embodiments, the plurality of additional ridges 106b can be part of a series of corrugated ridges.

[0125] FIG. 4 shows a series 410 of ridges 106b according to some embodiments. In some embodiments, series 410 can comprise a series of corrugated ridges 106b interspaced by grooves 414. In some embodiments, the grooves 414 can be defined by bottom surface 104.

[0126] As shown in FIG. 4, each ridge 106b can comprise a peak 412. A peak 412 of a ridge 106b can represent a point on the ridge 106b's protruding surface 222 that is farthest from a plane defined by corresponding edges 302, as measured in a direction perpendicular to the plane. When a ridge 106b has multiple points on its protruding surface 222 that are farthest from and equidistant from the plane defined by edges 302, its peak 412 is the geometric center of these points.

[0127] In some embodiments, series 410 can comprise a distance dP between peaks 412 of adjacent ridges 106b. In some embodiments, dP can be greater than or equal to 0.5 mm and less than or equal to 20 mm. More specifically, in some embodiments, dP can be greater than or equal to 0.5 mm and less than or equal to 15 mm, greater than or equal to 0.5 mm and less than or equal to 10 mm, greater than or equal to 0.5 mm and less than or equal to 8 mm, greater than or equal to 0.5 mm and less than or equal to 6 mm, greater than or equal to 0.5 mm and less than or equal to 4 mm, greater than or equal to 0.5 mm and less than or equal to 2.5 mm, or greater than or equal to 0.5 mm and less than or equal to 1 mm. Any of the above ranges for dP can apply to one, some, or all pairs of adjacent ridges 106b in series 410.

[0128] As used herein, the term “series of corrugated ridges” refers to a group of ridges 106b within which each pair of adjacent ridges 106b satisfies the following conditions: 1) the ridges 106b of the pair are substantially parallel to and lie at least partially alongside one another, and 2) the distance dP between peaks 412 of the pair is less than or equal to three times the maximum width wMAX of the widest ridge 106b of the pair. The group of ridges 106b can be two or more ridges 106b.

[0129] In some embodiments, series 410 can be within rearfoot portion 140. In some embodiments, series 410 can be within forefoot portion 130. In some embodiments, series 410 can span across the boundary between the rearfoot portion 140 and the forefoot portion 130.

[0130] In some embodiments, one or more ridges 106b of series 410 can be arranged substantially parallel to longitudinal axis LP of metal plate 101, shown extending into the page in FIG. 4. In such embodiments, lengthwise axes LR of the one or more ridges 106b extend substantially parallel to longitudinal axis LP of metal plate 101. Accordingly, in some embodiments, lengthwise axes LR of the one or more ridges 106b can extend substantially in a direction from a forefoot end (for example, forefoot end 902) to a heel end (for example, heel end 904) of an article of footwear (for example, article of footwear 900 shown in FIG. 9) when metal plate 101 is comprised by the article of footwear.

[0131] In some embodiments, as described herein, metal plate 101 can be sized and shaped to span only part of the area of a shoe sole. In some of such embodiments, longitudinal axis LP of metal plate 101, which extends along metal plate 101's longest dimension, may extend from lateral side 110 to medial side 120 of metal plate 101. In such embodiments, lengthwise axes LR of one or more ridges 106b of series 410 can extend substantially perpendicularly to longitudinal axis LP to extend substantially in the direction from the forefoot end to the heel end of the article of footwear when metal plate 101 is comprised by the article of footwear.

[0132] In some embodiments, series 410, or any single ridge 106b so arranged, can provide additional stiffness to the article of footwear along the direction from the forefoot end to the heel end when metal plate 101 is comprised by the article of footwear.

[0133] As used herein, a component or axis extending “substantially parallel” to another component or axis, or a component or axis extending “substantially in a direction,” means that the component or axis extends at an angle less than or equal to 10 degrees with respect to the other component, other axis, or the direction. As used herein, a component or axis extending “substantially perpendicularly” to another component or axis means that the component or axis extends at an angle greater than or equal to 80 degrees and less than or equal to 100 degrees with respect to the other component or other axis.

[0134] FIG. 5 shows another series 540 of ridges 106b according to some embodiments. In some embodiments, series 540 can comprise a series of corrugated ridges 106b interspaced by grooves 542.

[0135] In some embodiments, series 540 can be within forefoot portion 130. In some embodiments, series 540 can be within rearfoot portion 140. In some embodiments, series 540 can span across the boundary between rearfoot portion 140 and the forefoot portion 130.

[0136] As shown in FIG. 5, in some embodiments, one or more ridges 106b of series 540 can be arranged substantially perpendicular to longitudinal axis LP of metal plate 101. In such embodiments, lengthwise axes LR of the one or more ridges 106b extend substantially perpendicular to longitudinal axis LP of metal plate 101. Accordingly, in some embodiments, lengthwise axes LR of the one or more ridges 106b can extend substantially in a direction from a lateral side (for example, lateral side 910) to a medial side of an article of footwear (for example, article of footwear 900 shown in FIG. 9) when metal plate 101 is comprised by the article of footwear.

[0137] In some embodiments, as described herein, metal plate 101 can be sized and shaped to span only part of the area of a shoe sole. In some of such embodiments, longitudinal axis LP of metal plate 101, which extends along metal plate 101's longest dimension, may extend from lateral side 110 to medial side 120 of metal plate 101. In such embodiments, lengthwise axes LR of one or more ridges 106b of series 540 can extend substantially parallel to longitudinal axis LP to extend substantially in the direction from the lateral side to the medial side of the article of footwear when metal plate 101 is comprised by the article of footwear.

[0138] In some embodiments, series 540, or any single ridge 106b so arranged, can provide flexibility to the article of footwear along a direction from a forefoot end to a heel end of the article of footwear when metal plate 101 is comprised by the article of footwear.

[0139] In some embodiments, sole plate 100 comprises series 410 in addition to series 540. In some embodiments, sole plate 100 comprises only one of series 410 or series 540. In some embodiments, sole plate 100 comprises neither series 410 nor series 540.

[0140] FIG. 4 shows series 410 with longitudinally extending ridges 106b, as defined with respect to a full article of footwear, within rearfoot portion 140. FIG. 5 shows series 540 with latitudinally extending ridges 106b, as defined with respect to a full article of footwear, within forefoot portion 130. However, in some embodiments, metal plate 101 can comprise one or more longitudinally extending ridges 106b within forefoot portion 130, rearfoot portion 140, or both. In some embodiments, one or more longitudinally extending ridges 106b can extend across the boundary between forefoot portion 130 and rearfoot portion 140. Likewise, in some embodiments, metal plate 101 can comprise one or more latitudinally extending ridges 106bwithin forefoot portion 130, rearfoot portion 140, or both. In some embodiments, a latitudinally extending ridge 106b can lie on the boundary between forefoot portion 130 and rearfoot portion 140. In any of these embodiments, a ridge 106b can be isolated or part of a series of corrugated ridges, such as a series 410 or a series 540.

[0141] While FIGS. 4-5 shows four ridges 106b in series 410 and series 540, series 410 and / or series 540 can comprise any number of ridges 106b. In some embodiments, series 410 and / or series 540 can comprise greater than or equal to three ridges 106b and less than or equal to 50 ridges 106b. More specifically, in some embodiments, series 410 and / or series 540 can comprise greater than or equal to 4 ridges and less than or equal to 30 ridges, greater than or equal to 5 ridges and less than or equal to 25 ridges, greater than or equal to 6 ridges and less than or equal to 20 ridges, greater than or equal to 7 ridges and less than or equal to 20 ridges, greater than or equal to 8 ridges and less than or equal to 20 ridges, greater than or equal to 9 ridges and less than or equal to 20 ridges, greater than or equal to 10 ridges and less than or equal to 20 ridges, greater than or equal to 10 ridges and less than or equal to 18 ridges, greater than or equal to 12 ridges and less than or equal to 16 ridges, or about 15 ridges.

[0142] FIG. 6 shows a section view of metal plate 101, taken along line 6′-6′ in FIG. 5, according to some embodiments. FIG. 6 shows an embodiment of series 540 in more detail.

[0143] As shown in FIG. 6, in some embodiments, one or more ridges 106b of series 540 can be recessed from a plane PS defined by portions of bottom surface 104 surrounding series 540. In such embodiments, a gap between peaks 412 of the one or more ridges 106b and plane PS exists.

[0144] However, in some embodiments, one or more ridges 106b of series 540 need not be recessed from plane PS, but can be even with plane PS or extend beyond plane PS.

[0145] FIG. 7 shows sole plate 100 according to some embodiments. Protrusions 106 are not shown in FIG. 7; however, sole plate 100 can comprise protrusions 106 as shown and described in the context of FIGS. 1-6.

[0146] As shown in FIG. 7, in some embodiments, sole plate 100 can comprise one or more lateral wings 710 extending from lateral side 110 of metal plate 101. In some embodiments, sole plate 100 can comprise a first lateral wing 710a extending from lateral side 110 at forefoot portion 130. In some embodiments, sole plate 100 can comprise a second lateral wing 710b extending from lateral side 110 at rearfoot portion 140.

[0147] In some embodiments, sole plate 100 can comprise one or more medial wings 720 extending from medial side 120 of metal plate 101. In some embodiments, sole plate 100 can comprise a first medial wing 720a extending from medial side 120 at forefoot portion 130. In some embodiments, sole plate 100 can comprise a second medial wing 720b extending from medial side 120 at rearfoot portion 140.

[0148] In some embodiments, the one or more lateral wings 710 and / or the one or more medial wings 720 can be integrally formed with metal plate 101. Accordingly, in some embodiments, they can be formed from the same material and can form part of the same sheet used to manufacture metal plate 101.

[0149] In some embodiments, a void can pass through a wing 710, 720. For example, in some embodiments, a void 712 can pass through second lateral wing 710b and / or second medial wing 720b.

[0150] While FIG. 7 shows four total lateral and medial wings 710, 720 extending from metal plate 101, in some embodiments, additional lateral and / or medial wings 710, 720 can extend from metal plate 101. In some embodiments, fewer lateral and / or medial wings 710, 720, for example, any subset of the four shown, can extend from metal plate 101.

[0151] Additionally, while FIG. 7 shows lateral and medial wings 710, 720 extending from lateral and medial sides 110, 120 of metal plate 101, respectively, in some embodiments, sole plate 100 can comprise one or more wings extending other directions and from other portions of metal plate 101, for example, rearward from a heel portion of metal plate 101 and / or frontward from a toe portion of metal plate 101.

[0152] FIG. 8 shows a section view of sole plate 100, taken along line 8′-8′ in FIG. 7 and viewed from the forefoot end of metal plate 101, according to some embodiments. As shown in FIG. 8, in some embodiments, first lateral wing 710a and first medial wing 720a can be bent in a direction above top surface 102 of metal plate 101. The same can be true of second lateral wing 710b and second medial wing 720b, or any wing extending from metal plate 101.

[0153] FIGS. 9-10 shows an article of footwear 900 comprising sole plate 100 according to some embodiments. In some embodiments, article of footwear 900 can be an article of athletic footwear. For example, in some embodiments, article of footwear 900 can be a soccer shoe, a track shoe, or an American football shoe. However, article of footwear 900 is not limited to these types of shoes.

[0154] While FIGS. 9-10 show sole plate 100 having one or more lateral wings 710 extending from metal plate 101, in some embodiments, sole plate 100 comprised by article of footwear 900 can comprise no wings 710, 720, as shown in FIG. 1.

[0155] As shown in FIG. 9, article of footwear 900 can comprise an upper 920. Upper 920 can be formed from any known materials and can be configured to receive a foot of a wearer. In some embodiments, metal plate 101 can be coupled to upper 920, for example, via a midsole, using adhesive, rivets, snap fit components, lacing, and / or stitching (for example, using holes bored through metal plate 101). In some embodiments, upper 920 can comprise metallic threads or other components that can be welded to metal plate 101. In some embodiments, depending on the materials it comprises, upper 920 can be coupled to metal plate 101 using any of the methods described herein for coupling a polymer or metal component to a metal plate 101.

[0156] In some embodiments, lateral and / or medial wings 710, 720 can be coupled to upper 920 via adhesive, rivets, and / or stitching (for example, using holes bored through the wing(s)). In some embodiments, lateral and / or medial wings 710, 720 can be configured to provide support to upper 920. For example, lateral and / or medial wings 710, 720 can provide additional stiffness to upper 920.

[0157] In some embodiments, lateral and / or medial wings 710, 720 can be configured to provide support to a side of upper 920, for example, a lateral side 910 and / or a medial side (opposite lateral side 910 and not shown in FIGS. 9-10). In some embodiments, sole plate 100 can comprise only lateral wing(s) 710 providing support to lateral side 910 of upper 920, and no medial wings 720. In some embodiments, sole plate 100 can comprise more and / or larger lateral wing(s) 710 as compared to medial wing(s) 720, such that more support is provided to lateral side 910 than to the medial side of upper 920.

[0158] Additionally or alternatively, in some embodiments, a lateral and / or medial wing 710, 720 can be configured as a heel counter. For example, FIG. 10 shows lateral wing 710 providing support to a heel portion of article of footwear 900 and serving as at least a partial heel counter.

[0159] In some embodiments, sole plate 100 can comprise a wing that extends rearward of metal plate 101 when sole plate 100 is formed and is configured as a full heel counter.

[0160] In some embodiments, sole plate 100 can comprise a wing that extends frontward of metal plate 101 when sole plate 100 is formed and is configured as a toe bumper. When bent toward top surface 102, the frontward wing can reinforce forefoot end 902 of article of footwear 900 and can provide protection to upper 920 and / or a foot of a wearer against abrasion and / or impact.

[0161] In some embodiments, sole plate 100 can conform to the shape of upper 920 and / or a midsole. For example, in some embodiments, no empty space exists between upper 920 and / or the midsole and metal plate 101. Additionally or alternatively, in some embodiments, no empty space exists between upper 920 and / or the midsole and wings 710, 720.

[0162] While FIGS. 9-10 show lateral side 910 of article of footwear 900, in some embodiments, the configuration of wings shown in FIG. 9 can be implemented on a medial side of article of footwear 900. Likewise, in some embodiments, the configuration of the wing shown in FIG. 10 can be implemented on a medial side of article of footwear 900. In some embodiments, the configuration of wings shown in FIG. 9 can be implemented on lateral side 910 of article of footwear 900 while the configuration of the wing shown in FIG. 10 can be implemented on the medial side of article of footwear 900, or vice-versa.

[0163] FIG. 11A shows a sole plate 1100 according to some embodiments. In some embodiments, sole plate 1100 can comprise a metal plate 1101 configured for a basketball shoe.

[0164] In some embodiments, metal plate 1101 can comprise a base 1102 and prongs 1104 extending from the base 1102. Prongs 1104a-b, configured to extend toward a forefoot end of an article of footwear, can define a void 1108a between prongs 1104a-b. Prongs 1104c-d, configured to extend toward a heel end of an article of footwear, can define a void 1108b between prongs 1104c-d.

[0165] Prongs 1104 can each comprise a distal tip 1106. In some embodiments, a distance between distal tips 1106a-b of prongs 1104a-b can be shorter than a distance across void 1108a at its widest point. In some embodiments, a distance between distal tips 1106c-d of prongs 1104c-d can be shorter than a distance across void 1108b at its widest point.

[0166] Metal plate 1101 can comprise any of the metal types and thickness described above for metal plate 101.

[0167] In some embodiments, metal plate 1101 can comprise ridges 106b as described above for metal plate 101.

[0168] In some embodiments, sole plate 1100 can comprise wings extending from metal plate 1101, the wings being the same or similar to wings 710, 720.

[0169] FIG. 11B shows a sole plate 1110 according to some embodiments. In some embodiments, sole plate 1110 can comprise a metal plate 1111 configured for a running shoe.

[0170] In some embodiments, metal plate 1111 can comprise a base 1112 and prongs 1114 extending from the base 1112. Prongs 1114a-e, configured to extend toward a forefoot end of an article of footwear, can define voids 1118a-d between pairs of prongs 1114a-e.

[0171] Prongs 1114a-e can each comprise a distal tip 1116a-e, respectively. In some embodiments, a distance between distal tips 1116 (for example, distal tips 1116a-b) of a pair of adjacent prongs 1114 (for example, prongs 1114a-b) can be shorter than a distance across a corresponding void 1118 (for example, void 1118a) at its widest point, the corresponding void being defined by the pair of adjacent prongs 1114.

[0172] Metal plate 1111 can comprise any of the metal types and thickness described above for metal plate 101.

[0173] In some embodiments, metal plate 1111 can comprise ridges 106b as described above for metal plate 101.

[0174] In some embodiments, sole plate 1110 can comprise wings extending from metal plate 1111, the wings being the same or similar to wings 710, 720.

[0175] FIG. 12 shows a method 1200 of making a sole plate (for example, sole plate 100) for an article of footwear (for example, article of footwear 900), according to some embodiments.

[0176] Unless stated otherwise, the steps of method 1200 need not be performed in the order set forth herein. Additionally, unless specified otherwise, the steps of method 1200 need not be performed sequentially. The steps can be performed in a different order or simultaneously. For example, step1220 can be performed before, after, or simultaneous with step 1210. Additionally, method 1200 need not comprise all steps shown in FIG. 12. For example, method 1200 need not comprise step 1220, for example, if a substantially flat metal plate is used. Likewise, method 1200 need not comprise step 1230, for example, if the sole plate comprises no medial or lateral wings.

[0177] Step 1210 comprises forming a protrusion (for example, a protrusion 106) in a metal plate (for example, metal plate 101). In some embodiments, the forming can comprise a process chosen from stamping, deep drawing, and incremental sheet forming (ISF). For each of these processes, the use of a sheet metal material provides for smaller draw angles and therefore more extreme geometries, as compared to a polymeric material. For example, sole structures having the wall thicknesses, thickness deviations, and widths described herein can form functional cleats and ridges.

[0178] Step 1220 comprises shaping the metal plate. In some embodiments, shaping the metal plate can be performed while forming the protrusion in step 1210. In some embodiments, shaping the metal plate can comprise forming a concave curvature in a perimeter area (for example, perimeter area 240) of a top surface (for example, top surface 102) of the metal plate.

[0179] In some embodiments, for example, if the sole plate comprises a lateral wing (for example, a lateral wing 710) and / or a medial wing (for example, a medial wing 720), method 1200 can comprise step 1230 of bending the lateral wing in a direction above the top surface of the metal plate and / or bending the medial wing in a direction above the top surface of the metal plate. In some embodiments, step 1230 can be performed sequentially (before or after) or simultaneously with step1220.

[0180] In some embodiments, method 1200 can comprise a step of forming a variable plate thickness tP in the metal plate. In some embodiments, the step of forming a variable plate thickness tP can comprise a process chosen from roller milling, stamping, and laser ablation. In some embodiments, the step of forming a variable plate thickness tP can comprise forging, either by a producer of sole plates as described herein or by a third party, the metal plate to comprise a variable plate thickness tP. In some embodiments, the step of forming a variable plate thickness can be performed before step 1210.

[0181] In some embodiments, the step of forming a variable plate thickness tP can comprise selectively thinning the metal plate in a forefoot portion (for example, forefoot portion 130). In some embodiments, the step of forming a variable plate thickness tP can comprise selectively thinning the metal plate in a rearfoot portion (for example, rearfoot portion 130).

[0182] In some embodiments, the step of forming a variable plate thickness tP can comprise selectively thinning the metal plate in regions other than, for example, regions adjacent to, those selected to form protrusions 106. An example region 160 adjacent to a region selected to form a protrusion 106 is shown in FIG. 1. In such embodiments, plate thickness tP at the regions selected to form protrusions 106 can be greater than plate thickness tP in adjacent regions. Once the stamping, deep drawing, or ISF process used to create a protrusion 106 is complete, thereby thinning metal plate 101 at the region selected to form the protrusion 106, the earlier selective thinning of an adjacent region (for example, region 160) can cause the protrusion 106 to comprise a wall thickness tW that is substantially equal to (for example, less than or equal to a 10% difference) plate thickness tP in the adjacent region. In some embodiments, a deviation between the wall thickness tW and plate thickness tP in the adjacent region can be ±50 microns, ±25 microns, ±15 microns, ±10 microns, or ±5 microns. A deviation of ±5 microns between the wall thickness tW and plate thickness tP, for example, means that the wall thickness tW is not more than 5 microns greater than or less than the plate thickness tP in the adjacent region.

[0183] References to selective thinning of the metal plate in regions adjacent to those selected to form protrusions 106 does not imply that the metal plate is thinned only in those adjacent regions.

[0184] In some embodiments, method 1200 can comprise a step of stacking multiple metal plates before forming the protrusion. In such embodiments, protrusions can be formed in the multiple metal plates simultaneously using one of the stamping, deep drawing, or ISF processes. As noted herein, plate thickness tP can be significantly less than a thickness of a polymer component. This can enable protrusions to be formed in multiple metal plates simultaneously with only negligible deviation in the geometries of the protrusions between plates.

[0185] In some embodiments, method 1200 can comprise a step of forming a micro surface texture (for example, the micro surface texture of surface configuration 1520 described herein) in the metal plate. In some embodiments, the step of forming the micro surface texture can comprise a process chosen from laser ablation, etching (for example, chemical etching), and roller milling.

[0186] FIGS. 13A-C show a mold 1300 for performing steps 1210 and / or 1220 of method 1200 according to some embodiments. For example, mold 1300 can be used in a stamping process.

[0187] Mold 1300 can comprise a first side 1310. In some embodiments, first side 1310 can be a positive side comprising projections 1312 to form protrusions 106 in metal plate 101.

[0188] In some embodiments, mold 1300 can comprise a second side 1320. In some embodiments, second side 1320 can be a negative side comprising receptacles 1322 to receive protrusions 106. In some embodiments, mold 1300 need not comprise second side 1320 comprising receptacles 1322. Instead, second side 1320 can comprise a foam or another compressible material to receive protrusions 106.

[0189] While first and second sides 1310, 1320 have been described as “positive” and “negative” sides, in some embodiments, first and / or second sides 1310, 1320 can comprise both one or more projections 1312 and one or more receptacles 1322. In some of such embodiments, the projections 1312 and receptacles 1322 of one side 1310, 1320 can be configured to shape metal plate 101 of sole plate 100 and / or form other structural features.

[0190] In some embodiments, first side 1310 can comprise a receptacle 1322 that comprises projections 1312 at the bottom of the receptacle 1322. Simultaneously, in some embodiments, second side 1320 can comprise a projection 1312 that comprises receptacles 1322 along the metal plate 101-facing surface of the projection 1312. Such an arrangement on first and second sides 1310, 1320 can be used, for example, to form series 540 shown in FIG. 6. The projections 1312 comprised by the receptacle 1322 on first side 1310 can be used to form ridges 106b shown in FIG. 6, while the receptacles 1322 comprised by the projection 1312 on second side 1320 can receive the ridges 106b. The projection 1312 on second side 1320 can cause ridges 106b to be recessed from plane PS shown in FIG. 6. Accordingly, in some embodiments, a series 540 of ridges 106b recessed from plane PS can be formed in a single stamping step.

[0191] In some embodiments, a series 540 of ridges 106b recessed from plane PS can be formed in multiple stamping steps, for example, by first forming a bump on top surface 102 in a first stamping step, and then stamping the bump to form ridges 106b in a second stamping step.

[0192] Metal plate 101 in FIG. 13A can comprise a sheet metal component comprising any of the metals and thicknesses described herein for metal plate 101. In embodiments implementing stamping, metal plate 101 can be formed into its final product as shown in FIGS. 13B-C by inserting the sheet metal component into mold 1300 and pressing first side 1310 and / or second side 1320 into the sheet metal component.

[0193] While FIGS. 13A-C show a cross section of metal plate 101 that cuts across five protrusions 106, mold 1300 can be configured to form any number and configuration of protrusions 106 in metal plate 101.

[0194] While FIGS. 13A-C show a single metal plate 101 in mold 1300, in some embodiments, multiple metal plates 101 can be stacked and inserted simultaneously into mold 1300 to simultaneously form protrusions 106 in the multiple metal plates 101.

[0195] FIG. 14 shows a sheet 1400 according to some embodiments. As shown in FIG. 14, in some embodiments, multiple metal plates 101 can be formed in a single sheet 1400. In some embodiments, sheet 1400 can be inserted into a mold such as mold 1300 to form the multiple metal plates 101 simultaneously. In some embodiments, metal plates 101 of sheet 1400 can all be the same size, configured to fit the same size shoe. In some embodiments, two or more of metal plates 101 of sheet 1400 can be different sizes, configured to fit different size shoes.

[0196] Sheet 1400 can comprise a frame 1410 that jointly holds the multiple metal plates 101. The metal plates 101 can be cut from frame 1410 before being integrated into an article of footwear.

[0197] FIG. 15 shows various surface configurations for metal plate 101. For example, metal plate 101 can comprise a surface configuration 1510, a surface configuration 1520, a surface configuration 1530, a surface configuration 1540, a surface configuration 1550, or any combination thereof. Metal plate 101 can comprise any of surface configurations 1510, 1520, 1530, 1540, and / or 1550 at any region of metal plate 101.

[0198] Surface configuration 1510 comprises a flat sheet. In surface configuration 1510, top and bottom surfaces 102, 104 of metal plate 101 are substantially planar.

[0199] Surface configuration 1520 comprises a micro surface texture on top surface 102 and / or bottom surface 104. For example, in some embodiments, surface configuration 1520 can comprise furrows 1522 (areas having a first thickness tP1 of plate thickness tP) and beams 1524 (areas having a second, larger thickness tP2 of plate thickness tP) that form a micro pattern on top surface 102 and / or bottom surface 104. In some embodiments, furrows 1522 can be separated from one another by less than 2 mm (and by as little as 0.01 mm) and beams 1524 can be separated from one another by less than 2 mm (and by as little as 0.01 mm). In some embodiments, a depth of one or more furrows 1522 can be greater than or equal to ¼ and less than or equal to ½ of second thickness tP2. Furrows 1522 and beams 1524 have lengthwise axes extending into the page in the view of FIG. 15.

[0200] The furrows 1522 and beams 1524 of surface configuration 1520 are formed solely by variation of plate thickness tP, and not the bending of metal plate 101 as for cleats 106a and ridges 106b. In some embodiments, the variation of plate thickness tP in surface configuration 1520 can be achieved through laser ablation, etching (for example, chemical etching), or roller milling. In some embodiments of metal plate 101 comprising surface configuration 1520, a deviation of plate thickness tP can be any of the values across any of the percentages ranges of the area and / or regions of metal plate 101 disclosed herein, excluding deviations caused by furrows 1522 in the calculation.

[0201] Surface configuration 1520 can provide increased stiffness (relative to surface configuration 1510 having a plate thickness tP that matches first thickness tP1 of surface configuration 1520) along an axis B1 parallel to its beams 1524. Surface configuration 1520 can provide increased flexibility (relative to surface configuration 1510 having a plate thickness tP that matches second thickness tP2 of surface configuration 1520) along an axis B2 perpendicular to its beams 1524.

[0202] Surface configuration 1530 can comprise a micro corrugation. The micro corrugation can comprise a series (for example, like series 410 and / or 540) of corrugated ridges 106b interspaced by grooves 1532. In some embodiments, a maximum distance between peaks dP of adjacent ridges 106b in a “micro” corrugation can be less than or equal to 2 mm.

[0203] Surface configuration 1530 can provide increased stiffness (relative to surface configuration 1510) along a direction parallel to lengthwise axes LR of its ridges 106b. Surface configuration 1530 can provide increased flexibility (relative to surface configuration 1510) along a direction perpendicular to lengthwise axes LR of its ridges 106b.

[0204] Surface configuration 1540 can comprise a macro corrugation. The macro corrugation can comprise a series (for example, like series 410 and / or 540) of corrugated ridges 106b interspaced by grooves 1542. However, in comparison to surface configuration 1530, the maximum depths dMAX of cavities defined by ridges 106b and / or the distance between peaks dP of adjacent ridges 106b of surface configuration 1540 can be larger than for surface configuration 1530. In some embodiments, a maximum depth dMAX of cavities of ridges 106b in a “macro” corrugation can be greater than or equal to ## mm. However, the concept of a “micro” and “macro” corrugations can more generally refer to a smaller corrugation (surface configuration 1530) being embedded in a larger corrugation (surface configuration 1540) to form surface configuration 1550.

[0205] Surface configuration 1540 can provide increased stiffness (relative to surface configuration 1510) along a direction parallel to lengthwise axes LR of its ridges 106b. Surface configuration 1540 can provide increased flexibility (relative to surface configuration 1510) along a direction perpendicular to lengthwise axes LR of its ridges 106b.

[0206] Surface configuration 1550 can comprise a combination of surface configuration 1530 and surface configuration 1540. For example, surface configuration 1550 can comprise a series of corrugated ridges 106b-1 interspaced by grooves 1542, wherein each ridge 106b-1 and groove 1542 in the series itself comprises a series of corrugated ridges 106b-2 interspaced by grooves 1532. In surface configuration 1550, the maximum depths dMAX of cavities defined by ridges 106b-1 and / or the distance between peaks dP of adjacent ridges 106b-1 are substantially larger than the maximum depths dMAX of cavities defined by ridges 106b-2 and / or the distance between peaks dP of adjacent ridges 106b-2, as shown in FIG. 15.

[0207] Surface configuration 1550 can provide increased stiffness (relative to surface configuration 1510 and surface configurations 1530, 1540) along a direction parallel to lengthwise axes LR of its ridges 106b-1, 106b-2. Surface configuration 1550 can provide increased flexibility (relative to surface configuration 1510 and surface configurations 1530, 1540) along a direction perpendicular to lengthwise axes LR of its ridges 106b-1, 106b-2.

[0208] Any of surface configurations 1510-1550 can be disposed at any region of metal plate 101 to influence the characteristics of metal plate 101 in the region. For example, any of surface configurations 1520-1550 can be disposed at any region of metal plate 101 to increase stiffness and flexibility along particular axes / directions, depending on their orientations.

[0209] FIG. 16 shows metal plate 101 comprising different surface configurations (and / or differently oriented surface configurations) in different regions of metal plate 101. For example, metal plate 101 can comprise a surface configuration 1610 in forefoot portion 130 and a surface configuration 1620 in rearfoot portion 140, or vice versa.

[0210] In some embodiments, surface configuration 1610 can comprise surface configuration 1520 having beams 1524 arranged substantially perpendicular to longitudinal axis LP of metal plate 101. In some embodiments, surface configuration 1610 can comprise surface configuration 1530 having ridges 106b arranged substantially perpendicular to longitudinal axis LP of metal plate 101. In some embodiments, surface configuration 1610 can comprise surface configuration 1540 having ridges 106b arranged substantially perpendicular to longitudinal axis LP of metal plate 101. In some embodiments, surface configuration 1610 can comprise surface configuration 1550 having ridges 106b-1, 106b-2 arranged substantially perpendicular to longitudinal axis LP of metal plate 101. While FIG. 16 shows surface configuration 1610 covering nearly all of forefoot portion 130, in some embodiments, surface configuration 1610 can cover any subset of forefoot portion 130.

[0211] In some embodiments, surface configuration 1620 can comprise surface configuration 1520 having beams 1524 arranged substantially parallel to longitudinal axis LP of metal plate 101. In some embodiments, surface configuration 1620 can comprise surface configuration 1530 having ridges 106b arranged substantially parallel to longitudinal axis LP of metal plate 101. In some embodiments, surface configuration 1620 can comprise surface configuration 1540 having ridges 106b arranged substantially parallel to longitudinal axis LP of metal plate 101. In some embodiments, surface configuration 1620 can comprise surface configuration 1550 having ridges 106b-1, 106b-2 arranged substantially parallel to longitudinal axis LP of metal plate 101. While FIG. 16 shows surface configuration 1620 covering all of rearfoot portion 140, in some embodiments, surface configuration 1620 can cover any subset of rearfoot portion 140.

[0212] In some embodiments, the configuration shown in FIG. 16 can provide increased stiffness in rearfoot portion 140 and increased flexibility in forefoot portion 130 along longitudinal axis LP of metal plate 101, which can be useful for allowing flexion in a forefoot of a user during athletic activity while supporting the user's midfoot and heel.

[0213] FIGS. 17A-17B show one or more polymer segments 1710 coupling multiple metal plates 101, according to some embodiments. In some embodiments, sole plate 100 can comprise multiple metal plates 101a, 101b, etc. For example, in some embodiments, sole plate 100 can comprise a first metal plate 101a and a second metal plate 101b as shown in FIG. 17A. In some embodiments, sole plate 100 can comprise a first metal plate 101a, a second metal plate 101b, and a third metal plate 101c arranged between first and second metal plates 101a-b, as shown in FIG. 17B. First, second, and / or third metal plates 101a-c can comprise the same or similar features (for example, protrusions 106) as those described for metal plate 101 with respect to FIGS. 1-16.

[0214] In some embodiments, first metal plate 101a can be configured to occupy all or a portion of a rear half of an article of footwear (for example, article of footwear 900 shown in FIG. 9). In some embodiments, second metal plate 101b and third metal plate 101c can be configured to occupy all or a portion of a front half of the article of footwear. Accordingly, in some embodiments, one or more polymer segments 1710 coupling first and second metal plates 101a-b and optionally third metal plate 101c can be positioned in the front half of the article of footwear of which they form a part. In some embodiments, first metal plate 101a can extend to a heel end (for example, heel end 904) of the article of footwear of which it forms a part. In some embodiments, second metal plate 101b can extend to a forefoot end (for example, forefoot end 902) of the article of footwear of which it forms a part.

[0215] In some embodiments, one or more of first, second, and third metal plates 101a-c can be sized to extend from a lateral side (for example, lateral side 910) to a medial side of the article of footwear of which it forms a part.

[0216] In some embodiments, first and second metal plates 101a-b can collectively be sized to span greater than 50 percent of the area of a sole of the article of footwear, for example, greater than 60 percent, greater than 70 percent, greater than 80 percent, greater than 90 percent, or greater than 95 percent of the area of a sole of the article of footwear. In some embodiments, first, second, and third metal plates 101a-c can collectively be sized in the same manner.

[0217] In some embodiments, sole plate 100 can comprise one or more polymer segments 1710 coupling the multiple metal plates 101. In some embodiments, a polymer segment 1710 can comprise a polymer plate. In some embodiments, a polymer segment 1710 coupling two metal plates 101 can comprise TPU, nylon, polypropylene (PP), rubber, and / or ethylene vinyl acetate (EVA). In some embodiments, a polymer segment 1710 can be a 3D printed part, for example, comprising a lattice structure.

[0218] In some embodiments, a polymer segment 1710 can couple first metal plate 101a to second metal plate 101b while leaving a gap 1720 between first and second metal plates 101a-b, as shown in FIG. 17A.

[0219] In some embodiments, sole plate 100 can comprise multiple polymer segments 1710, as shown in FIG. 17B. For example, sole plate 100 can comprise a first polymer segment 1710a coupling first metal plate 101a to third metal plate 101c. In addition, sole plate 100 can comprise a second polymer segment 1710b coupling second metal plate 101b to third metal plate 101c. In some embodiments, a gap 1720 can exist between metal plates 101 coupled by a polymer segment 1710. In some embodiments, the gap 1720 can extend from a medial side to a lateral side of adjacent metal plates 101, as shown in FIGS. 17A-B.

[0220] The one or more polymer segments 1710 shown in FIGS. 17A-B can provide increased flexibility to specific areas of sole plate 100. For example, the configuration shown in FIGS. 17A-B can maintain stiffness in portions of sole plate 100 configured to occupy a rear half of an article of footwear while increasing flexibility in portions of sole plate 100 configured to occupy a front half of the article of footwear. This can be useful for allowing flexion in a forefoot of a user during athletic activity while supporting the user's midfoot and heel.

[0221] FIG. 18 shows various configurations for coupling a metal plate 101 to a polymer segment 1710, according to some embodiments. In some embodiments, the one or more polymer segments 1710 shown in FIGS. 17A-B can be bonded to multiple metal plates 101 as shown in FIGS. 17A-17B using any of the configurations described herein.

[0222] In a first coupling configuration 1810, a polymer segment 1710 can overlap a metal plate 101 (for example, first metal plate 101a and / or third metal plate 101c) on both top surface 102 and bottom surface 104 of the metal plate 101. In some embodiments, the polymer segment 1710 can be fixed to the metal plate 101 by adhesive. In some embodiments, the polymer segment 1710 can be fixed to the metal plate 101 by thermal bonding, for example, heat staking, ultrasonic welding, induction welding, or laser welding. In some embodiments, the polymer segment 1710 can be fixed to the metal plate 101 by overmolding (for example, injection molding) the polymer segment 1710 on the metal plate 101.

[0223] In a second coupling configuration 1820, a polymer segment 1710 can be mechanically interlocked with a metal plate 101 (for example, first metal plate 101a). In such embodiments, apertures 1822 can be formed in the metal plate 101. The polymer segment 1710 can comprise flared locking protrusions 1824. In some embodiments, locking protrusions 1824 can be compressed and inserted through apertures 1822 from either a bottom surface 104-side (as shown) or a top surface 102-side of the metal plate 101, according to preference. Locking protrusions 1824 can extend through apertures 1822 and abut either top surface 102 or bottom surface 104 to lock the polymer segment 1710 to the metal plate 101. Alternatively or additionally, in some embodiments, the polymer segment 1710 can be fixed to the metal plate 101 using any of the techniques described for first coupling configuration 1810.

[0224] In a third coupling configuration 1830, a metal plate 101 (for example, first metal plate 101a) can comprise second surface configuration 1520 described with respect to FIG. 15. Second surface configuration 1520 can be on top surface 102, bottom surface 104, or both, according to preference. The furrows 1522 and beams 1524 of second surface configuration 1520 can provide an increased surface area to which a polymer segment 1710 can be bonded. The polymer segment 1710 can be fixed to the metal plate 101 using any of the techniques described for first coupling configuration 1810.

[0225] In a fourth coupling configuration 1840, a metal plate 101 (for example, first metal plate 101a) can comprise a hooked portion 1826. Hooked portion 1826 can be a portion of the metal plate 101 that curves toward and extends over top surface 102 or bottom surface 104 of adjacent portions of metal plate 101, according to preference. In some embodiments, hooked portion 1826 can extend substantially parallel to top surface 102 or bottom surface 104. In some embodiments, hooked portion 1826 can form a cavity 1828. The polymer segment 1710 can be fixed to the metal plate 101 by overmolding (for example, injection molding) the polymer segment 1710 on the metal plate 101. Portions of the polymer segment 1710 can be arranged inside cavity 1828, locking the polymer segment to the metal plate 101.

[0226] FIGS. 19A-19C show various configurations for cleats 106a, according to some embodiments. While in some embodiments cleats 106a can be formed by metal plate 101 alone, in some embodiments, a polymer segment 1710 can at least partially form a cleat 106a, as shown in FIGS. 19A-19C. Accordingly, a protrusion 106 can comprise a cleat 106a and / or be comprised by a cleat 106a.

[0227] In a first cleat configuration 1910 shown in FIG. 19A, a metal plate 101 can comprise little or no curvature at a point of coupling to a polymer segment 1710. Accordingly, the polymer segment 1710 can entirely form a cleat 106a. The polymer segment 1710 can be coupled to the metal plate 101 using any of first-fourth coupling configurations 1810-1840 described with respect to FIG. 18.

[0228] When a polymer segment 1710 at least partially forms a cleat 106a, it can be coupled to a metal plate 101 using a variety of coupling means in addition to or alternatively to first-fourth coupling configurations 1810-1840. For example, coupling can be performed using a threaded polymer segment 1710 that screws into the metal plate 101. As another example, coupling can be performed by a snap fit of polymer segment 1710 and the metal plate 101.

[0229] In a second cleat configuration 1920 shown in FIG. 19B, a metal plate 101 can comprise a cavity 210 and a bump 220 at a point of coupling to a polymer segment 1710. The polymer segment 1710 can be coupled to the bump 220. Accordingly, the polymer segment 1710 can only partially form a cleat 106a. For example, the polymer segment 1710 can form a tip of the cleat 106a. In some embodiments, the bump 220 can comprise an aperture 1822 for coupling of the polymer segment 1710. The polymer segment 1710 can be coupled to the metal plate 101 using any of first-fourth coupling configurations 1810-1840 described with respect to FIG. 18.

[0230] In some embodiments of second cleat configuration 1920, the polymer segment 1710 can extend a distance greater than or equal to the depth of cavity 210 beyond bump 220. In some embodiments, the polymer segment 1710 can extend a distance less than or equal to the depth of cavity 210 beyond bump 220.

[0231] In a third cleat configuration 1930 shown in FIG. 19C, a metal plate 101 can comprise a cavity 210 and a bump 220 at a point of coupling to a polymer segment 1710. The polymer segment 1710 can be coupled to the bump 220. Accordingly, the polymer segment 1710 can only partially form a cleat 106a. In some embodiments, the bump 220 comprises no aperture for coupling of the polymer segment 1710. Instead the polymer segment 1710 can be coupled to the metal plate 101 entirely on protruding surface 222. In some embodiments, the polymer segment 1710 can be fixed to bump 220 by adhesive. In some embodiments, the polymer segment 1710 can be fixed to bump 220 by thermal bonding, for example, heat staking, ultrasonic welding, induction welding, or laser welding. In some embodiments, the polymer segment 1710 can be fixed to bump 220 by overmolding (for example, injection molding) the polymer segment 1710 on the metal plate 101. In some embodiments, the polymer segment 1710 can be fixed to bump 220 by dipping bump 220 in a molten polymer. In some embodiments, the polymer segment 1710 can be fixed to bump 220 by spraying or otherwise applying a liquid polymer to bump 220 and then curing the liquid polymer to a solid.

[0232] In some embodiments of the third cleat configuration 1930, the polymer segment 1710 can confirm to the shape of bump 220. In some embodiments, the polymer segment 1710 can cover greater than 50 percent of the area of protruding surface 222, for example, greater than 60 percent, greater than 70 percent, or greater than 80 percent.

[0233] In some embodiments of third cleat configuration 1930, the polymer segment 1710 can extend a distance less than the depth of cavity 210 beyond bump 220.

[0234] In some embodiments, a polymer segment 1710 at least partially forming a cleat 106a can comprise TPU.

[0235] Apart from being a composite of a metal plate 101 and a polymer segment 1710, cleats 106a shown in FIGS. 19A-19C can comprise the same or similar features (for example, size) as cleats 106a described with respect to FIGS. 1-16. The configurations of cleats 106a described with respect to FIGS. 19A-19C can be implemented on any metal plate 101 described herein.

[0236] FIG. 20 shows sole plate 100 comprising layered metal plates 101, according to some embodiments. In some embodiments, sole plate 100 can comprise a first metal plate 101a and a second metal plate 101b layered along a vertical direction extending out of the page in the view of FIG. 20. In some embodiments, first metal plate 101a can entirely overlap second metal plate 101b. In such embodiments, no portion of second metal plate 101b extends beyond perimeter edge 105 of first metal plate 101a.

[0237] In some embodiments, second metal plate 101b can be arranged on bottom surface 104 of first metal plate 101a. In some embodiments, second metal plate 101b can be arranged at rearfoot portion 140 of first metal plate 101a. In some embodiments, rearfoot portion 140 can overlap a majority of second metal plate 101b. In some embodiments, rearfoot portion 140 can entirely overlap second metal plate 101b.

[0238] In some embodiments, second metal plate 101b can be spaced from heel end (for example, heel end 904) of an article of footwear (for example, article of footwear 900) of which it forms a part by a distance of 15 percent or more of the length of the article of footwear. In some embodiments, second metal plate 101b can be spaced from forefoot end (for example, forefoot end 902) of the article of footwear of which it forms a part by a distance of 30 percent or more of the length of the article of footwear.

[0239] In some embodiments, second metal plate 101b can be coupled to first metal plate 101a at a first joining region 2010a and a second joining region 2010b. In some embodiments, first and second joining regions 2010a-b can be arranged on longitudinal axis LP of first metal plate 101a. Second metal plate 101b can be coupled to first metal plate 101a by welding (for example, arc welding, resistance welding, energy beam welding, ultrasonic welding, friction stir welding, oxy-acetylene welding, or magnetic pulse welding), soldering and brazing, rivets, bolts, snap fit, press fit, seaming, adhesive, electroplating, galvanic bonding, interference fit (for example, shrink fitting), 3D printing (for example, using laser sintering or electron beam melting), etc.

[0240] In some embodiments, first and second metal plates 101a-b can comprise the same material. In some embodiments, first and second metal plates 101a-b can comprise different materials. In some embodiments, second metal plate 101b can comprise a material that is stiffer than that of first metal plate 101a.

[0241] Second metal plate 101b can provide increased stiffness to selected areas of sole plate 100. For example, the configuration shown in FIG. 20 can increase stiffness in portions of sole plate 100 configured to occupy a middle portion and / or rear half of an article of footwear.

[0242] FIG. 21 shows a cross-section of sole plate 100 shown in FIG. 20, taken along line 21′-21′, according to some embodiments. As shown in FIG. 21, in some embodiments, a gap 2110 can exist between first and second metal plates 101a-b. Gap 2110 can be formed by the curvature of first metal plate 101a at a portion configured to support a wearer's arch. In some embodiments, second metal plate 101b can be substantially planar.

[0243] FIG. 22 shows a cross-section of sole plate 100 shown in FIG. 20, taken along line 22′-22′, according to some embodiments. As shown in FIG. 22, in some embodiments, second metal plate 101b can cover one or more ridges 106b. In some embodiments, second metal plate 101b can contact the one or more ridges 106b, forming multiple gaps 2110 adjacent the one or more ridges 106b.

[0244] FIG. 23 shows one or more metal segments 2310 coupling multiple metal plates 101, according to some embodiments. In some embodiments, sole plate 100 can comprise multiple metal plates 101a, 101b, etc. For example, in some embodiments, sole plate 100 can comprise a first metal plate 101a and a second metal plate 101b as shown in FIG. 17A. In some embodiments, sole plate 100 can comprise a first metal plate 101a, a second metal plate 101b, and a third metal plate 101c arranged between first and second metal plates 101a-b, as shown in FIG. 17B and FIG. 23. First, second, and / or third metal plates 101a-c can comprise the same or similar features as those described for first-third metal plates 101a-c with respect to FIGS. 17A-B.

[0245] In some embodiments, first metal plate 101a can be configured to occupy all or a portion of a rear half of an article of footwear (for example, article of footwear 900 shown in FIG. 9). In some embodiments, second metal plate 101b and third metal plate 101c can be configured to occupy all or a portion of a front half of the article of footwear. Accordingly, in some embodiments, one or more metal segments 2310 coupling first and second metal plates 101a-b and optionally third metal plate 101c can be positioned in the front half of the article of footwear of which they form a part. In some embodiments, first metal plate 101a can extend to a heel end (for example, heel end 904) of the article of footwear of which it forms a part. In some embodiments, second metal plate 101b can extend to a forefoot end (for example, forefoot end 902) of the article of footwear of which it forms a part.

[0246] In some embodiments, sole plate 100 can comprise one or more metal segments 2310 coupling the multiple metal plates 101. The one or more metal segments 2310 can be configured, by shape and / or material, to be more flexible than first-third metal plates 101a-c.

[0247] In some embodiments, first-third metal plates 101a-c and the one or more metal segments 2310 can comprise the same material. In some embodiments, first-third metal plates 101a-c and the one or more metal segments 2310 can comprise different materials. In some embodiments, the one or more metal segments 2310 can comprise material(s) that are more flexible than those of first-third metal plates 101a-c. In some embodiments, the one or more metal segments 2310 can comprise thicknesses less than those of first-third metal plates 101a-c.

[0248] In some embodiments, sole plate 100 can comprise a first metal segment 2310a coupling first metal plate 101a to third metal plate 101c. In addition, sole plate 100 can comprise a second metal segment 2310b coupling second metal plate 101b to third metal plate 101c.

[0249] In some embodiments, the one or more metal segments 2310 can be coupled to metal plates 101 by welding (for example, arc welding, resistance welding, energy beam welding, ultrasonic welding, friction stir welding, oxy-acetylene welding, or magnetic pulse welding), soldering and brazing, rivets, bolts, snap fit, press fit, seaming, adhesive, electroplating, galvanic bonding, interference fit (for example, shrink fitting), 3D printing (for example, using laser sintering or electron beam melting), etc.

[0250] FIG. 24 shows a cross-section of sole plate 100 shown in FIG. 23, taken along line 24′-24′, according to some embodiments. As shown in FIG. 24, in some embodiments, the one or more metal segments 2310 can be arranged on top surface 102 of the metal plates 101 to which they are coupled.

[0251] In some embodiments, a gap 2320 can exist between metal plates 101 coupled by a metal segment 2310. In some embodiments, the gap 2320 can extend from a medial side to a lateral side of adjacent metal plates 101, as shown in FIG. 23.

[0252] As shown in FIGS. 24 and 25, the one or more metal segments 2310 can comprise a shape configured to provide increased flexibility at gaps 2320, relative to a solid metal plate 101. For example, with reference to FIG. 25, a metal segment 2310 (for example, second metal segment 2310b) can comprise a first wall 2312a extending away from gap 2320 in a diagonal direction, a second wall 2312b extending away from gap 2320 in an opposing diagonal direction, and a third wall 2312c joining the first and second walls 2312a-b. The third wall 2312c can enclose the entrance to gap 2320 on top surface 102. First wall 2312a can be coupled to one metal plate 101 (for example, second metal plate 101b), while second wall 2312b can be coupled to another metal plate 101 (for example, third metal plate 101c). While FIG. 25 shows substantially planar first, second, and third walls 2312a-c, in some embodiments, a metal segment 2310 can comprise a curved surface such that first, second, and third walls 2312a-c connect at rounded corners.

[0253] As shown in FIG. 25, when a force F is applied to a metal plate 101 coupled to a metal segment 2310, the metal segment 2310 can enable the metal plate 101 to flex in the direction of the force. For example, the combination of second metal plate 101b and third metal plate 101c shown in FIG. 25 can flex more easily than if second and third metal plates 101b-c formed a single metal plate 101.

[0254] Accordingly, the one or more metal segments 2310 shown in FIGS. 23-25 can provide increased flexibility to specific areas of sole plate 100. For example, the configuration shown in FIGS. 23-24 can maintain stiffness in portions of sole plate 100 configured to occupy a rear half of an article of footwear while increasing flexibility in portions of sole plate 100 configured to occupy a front half of the article of footwear. This can be useful for allowing flexion in a forefoot of a user during athletic activity while supporting the user's midfoot and heel.

[0255] FIGS. 17-25 have shown various polymer and metal components that can be coupled to a metal plate 101. However, additional components can be coupled to a metal plate 101, either with or instead of the various components shown. For example, in some embodiments, a heel counter (polymer and / or metal) can be coupled to a metal plate 101 using any of the techniques for coupling a polymer or metal component to a metal plate 101 described herein. As another example, an upper cage (polymer and / or metal) can be coupled to a metal plate 101 using any of the techniques for coupling a polymer or metal component to a metal plate 101 described herein. In some embodiments, the upper cage can provide lateral support. In embodiments in which portions of sole plate 100 (for example, lateral and / or medial wings 710, 720) extend into the upper of a shoe incorporating sole plate 100, lace stays (polymer and / or metal) can be coupled to the portions using any of the techniques for coupling a polymer or metal component to a metal plate 101 described herein.

[0256] FIG. 26 shows a draping simulation 2600 according to some embodiments. As shown in FIG. 26, the draping simulation can be performed on a computing device with a first virtual model 2610 and a second virtual model 2620. First virtual model 2610 can comprise a flexible virtual material, for example, a virtual fabric. Second virtual model 2620 can comprise a rigid virtual material, for example, a virtual shoe outsole or last. First virtual model 2610 can be draped over second virtual model 2620 using a draping simulation executed on the computing device. Various computer-aided design (CAD) programs can be implemented to perform the draping simulation, including CLO3D®, Rhinoceros® 3D (for example, operating Grasshopper®), Houdini®, etc.

[0257] In some embodiments, second virtual model 2620 can comprise the general shape of a resulting outsole. For example, second virtual model 2620 can include a desired curvature and / or projections that mirror the shape of cleats and / or ridges. However, virtual model 2620 need not comprise the exact shape of the resulting outsole.

[0258] FIGS. 27A-B show a metal sheet 2700 according to some embodiments. Metal sheet 2700 can be a three-dimensional (3D) metal sheet comprising a bump 2710 and a cavity 2720. Metal sheet 2700 can be formed based on a shape of first virtual model 2610 in a draped configuration such as that shown in FIG. 26. For example, the shape of first virtual model 2610 in the draped configuration can be exported to a computer numerical control (CNC) machine that at least partially forms metal sheet 2700 and / or component(s) used to form metal sheet 2700 (for example, dies, molds, etc.). In some embodiments, metal sheet 2700 can be formed via stamping (single or multi-step), deep drawing, incremental sheet forming (ISF) (for example, single point ISF), and / or another sheet metal forming process.

[0259] As shown in FIG. 27A, a metal plate 101 as described herein can then be formed from metal sheet 2700 using any of the methods described (for example, stamping, deep drawing, and ISF). Because portions of metal sheet 2700 have already been formed to the general shape of the final metal plate 101, this second step of forming metal plate 101 can be performed more easily.

[0260] FIG. 28 shows a method 2800 of making a sole plate (for example, sole plate 100) for an article of footwear (for example, article of footwear 900), according to some embodiments.

[0261] Step 2810 comprises performing a draping simulation (for example, draping simulation 2600) using a first virtual model (for example, first virtual model 2610) and a second virtual model (for example, second virtual model 2620). The draping simulation can comprise virtually draping the first virtual model over the second virtual model.

[0262] Step 2820 comprises forming a three-dimensional (3D) metal sheet (for example, metal sheet 2700) based on a shape of the first virtual model in a draped configuration. In some embodiments, step 2820 can comprise exporting the shape of the first virtual model in the draped configuration to a CNC machine configured to form the 3D metal sheet and / or component(s) used to form the 3D metal sheet.

[0263] Step 2830 comprises shaping and / or cutting the 3D metal sheet. For example, the 3D metal sheet can be shaped and / or cut to form a metal plate (for example, a metal plate 101) for the sole plate. In some embodiments, step 2830 can comprise at least one process chosen from stamping, deep drawing, and ISF.

[0264] Method 2800 provides for the general shape of a metal plate (for example, a metal plate 101) for the sole plate to be formed in a first stage (comprising steps 2810-2820). The final metal plate can then be formed by refining the general shape in a second stage (comprising step 2830).

[0265] While various embodiments have been described herein, they have been presented by way of example, and not limitation. It should be apparent that adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It therefore will be apparent to one skilled in the art that various changes in form and detail can be made to the embodiments disclosed herein without departing from the spirit and scope of the present disclosure. The elements of the embodiments presented herein are not necessarily mutually exclusive, but can be interchanged to meet various situations as would be appreciated by one of skill in the art.

[0266] Where a range of numerical values comprising upper and lower values is recited herein, unless otherwise stated in specific circumstances, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the disclosure or claims be limited to the specific values recited when defining a range. Further, when an amount, concentration, or other value or parameter is given as a range, one or more ranges, or as list of upper values and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or value and any lower range limit or value, regardless of whether such pairs are separately disclosed.

[0267] The examples are illustrative, but not limiting, of the present disclosure. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the spirit and scope of the disclosure.

[0268] It is to be understood that the phraseology or terminology used herein is for the purpose of description and not of limitation. The breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined in accordance with the following claims and their equivalents.

Claims

1. A sole plate for an article of footwear, the sole plate comprising:a single piece, integrally formed metal plate comprising a top surface, a bottom surface, and a plate thickness measured from the top surface to the bottom surface; anda protrusion formed in the metal plate, the protrusion defining a cavity on the top surface of the metal plate and a bump on the bottom surface of the metal plate, and the protrusion comprising a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness measured from the cavity surface to the protruding surface,wherein the plate thickness is greater than or equal to 0.01 mm and less than or equal to 0.5 mm, andwherein the wall thickness is greater than or equal to 0.01 mm and less than or equal to 0.5 mm.

2. The sole plate of claim 1, wherein the cavity comprises a maximum depth greater than or equal to 0.5 mm and less than or equal to 22 mm.

3. The sole plate of claim 1, wherein a deviation of the plate thickness is ±200 microns across 50% or more of an area of the metal plate.

4. The sole plate of claim 1, wherein a deviation of the wall thickness of the protrusion is ±100 microns across 50% or more of an area of the protrusion.

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

6. The sole plate of claim 1, wherein the protrusion is comprised by a cleat.

7. The sole plate of claim 6, wherein:the sole plate comprises a plurality of additional protrusions;each additional protrusion is formed in the metal plate, defines a cavity on the top surface of the metal plate and a bump on the bottom surface of the metal plate, and comprises a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness, measured from the cavity surface to the protruding surface, greater than or equal to 0.01 mm and less than or equal to 0.5 mm; andeach additional protrusion is comprised by a cleat.

8. The sole plate of claim 1, wherein the protrusion is a ridge.

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

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

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

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

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

14. The sole plate of claim 1, wherein the metal plate is made of at least one metal chosen from a steel, a titanium alloy, aluminum, and brass.

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

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

17. The sole plate of claim 1, comprising a lateral wing extending from a lateral side of the metal plate and a medial wing extending from a medial side of the metal plate, the lateral and medial wings being integrally formed with the metal plate.

18. The sole plate of claim 17, wherein the lateral wing is bent in a direction above the top surface of the metal plate and the medial wing is bent in a direction above the top surface of the metal plate.

19. An article of footwear comprising:an upper; andthe sole plate according to claim 1 coupled to the upper.

20. A method of making a sole plate for an article of footwear, the method comprising:forming a protrusion in a metal plate comprising a top surface, a bottom surface, and a plate thickness, measured from the top surface to the bottom surface, greater than or equal to 0.01 mm and less than or equal to 0.5 mm,wherein the protrusion defines a cavity on the top surface of the metal plate and a bump on the bottom surface of the metal plate, and comprises a cavity surface defined by the top surface of the metal plate, a protruding surface defined by the bottom surface of the metal plate, and a wall thickness, measured from the cavity surface to the protruding surface, greater than or equal to 0.01 mm and less than or equal to 0.5 mm, andwherein the forming comprising a process chosen from stamping, deep drawing, and incremental sheet forming.

21. The method of claim 20, further comprising shaping the metal plate while forming the protrusion.

22. The method of claim 21, wherein shaping the metal plate comprises forming a concave curvature in a perimeter area of the top surface of the metal plate.

23. The method of claim 20, wherein the sole plate comprises a lateral wing extending from a lateral side of the metal plate and a medial wing extending from a medial side of the metal plate, the lateral and medial wings being integrally formed with the metal plate, the method further comprising bending the lateral wing in a direction above the top surface of the metal plate and bending the medial wing in a direction above the top surface of the metal plate.

24. The method of claim 20, wherein the protrusion is comprised by a cleat.

25. The method of claim 20, further comprising forming a variable plate thickness in the metal plate, the forming the variable plate thickness comprising selectively thinning a region of the metal plate adjacent a region selected to form the protrusion.

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