FOOTWEAR PLATE

• US 20180184757A1
• Filed: 02/26/2018
• Published: 07/05/2018
• Est. Priority Date: 07/20/2016
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Granted Patent: US 10,743,606 B2
• Time in Patent Office: Days
• CPC Class Codes: A41D 1/08 specially adapted for sporting purposes
• CPC Class Codes: A42B 1/00 Hats; Caps; Hoods
• CPC Class Codes: A42B 1/02 Hats; Stiff caps
• CPC Class Codes: A42B 3/06 Impact-absorbing shells, e.g. of crash helmets
• CPC Class Codes: A42B 3/063 using layered structures
• CPC Class Codes: A42B 3/08 Chin straps or similar retention devices
• CPC Class Codes: A43B 13/026 Composites, e.g. carbon fibre or aramid fibre; the sole, one or more sole layers or sole part being made of a composite
• CPC Class Codes: A43B 13/04 Plastics, rubber or vulcanised fibre
• CPC Class Codes: A43B 13/12 Soles with several layers of different materials
• CPC Class Codes: A43B 13/122 characterised by the outsole or external layer
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/127 the midsole being multilayer
• CPC Class Codes: A43B 13/141 with a part of the sole being flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 13/143 provided with wedged, concave or convex end portions, e.g. for improving roll-off of the foot
• CPC Class Codes: A43B 13/146 Concave end portions, e.g. with a cavity or cut-out portion
• CPC Class Codes: A43B 13/16 Pieced soles with several layers of different material A43B13/12
• CPC Class Codes: A43B 13/181 Resiliency achieved by the structure of the sole
• CPC Class Codes: A43B 13/186 Differential cushioning region, e.g. cushioning located under the ball of the foot resilient heel not included in the sole A43B21/26; resilient supports for the heel of the foot A43B21/32
• CPC Class Codes: A43B 13/188 Differential cushioning regions
• CPC Class Codes: A43B 13/189 filled with a non-compressible fluid, e.g. gel, water
• CPC Class Codes: A43B 13/20 : Pneumatic soles filled with a compressible fluid, e.g. air, gas inflatable linings for skiboots A43B5/0407
• CPC Class Codes: A43B 13/22 : Soles made slip-preventing or wear-resisting, e.g. by impregnation or spreading a wear-resisting layer
• CPC Class Codes: A43B 13/223 : Profiled soles
• CPC Class Codes: A43B 13/26 : projecting beyond the sole surface
• CPC Class Codes: A43B 13/32 : by adhesives
• CPC Class Codes: A43B 13/37 : Sole and heel units
• CPC Class Codes: A43B 13/42 : Filling materials located between the insole and outer sole; Stiffening materials
• CPC Class Codes: A43B 21/24 : characterised by the constructive form
• CPC Class Codes: A43B 23/0225 : Composite materials, e.g. material with a matrix
• CPC Class Codes: A43B 23/081 : Toe stiffeners
• CPC Class Codes: A43B 5/02 : Football boots or shoes, i.e. for soccer, football or rugby
• CPC Class Codes: A43B 5/06 : Running shoes; Track shoes
• CPC Class Codes: A43B 7/1445 : situated under the midfoot, i.e. the second, third or fourth metatarsal
• CPC Class Codes: A43B 7/145 : situated under the toes, i.e. the phalanges
• CPC Class Codes: A43B 7/148 : Recesses or holes filled with supports or pads
• CPC Class Codes: A43B 7/18 : Joint supports, e.g. instep supports
• CPC Class Codes: A43B 9/02 : Footwear stitched or nailed through
• CPC Class Codes: A43C 15/02 : attached to the sole
• CPC Class Codes: A43C 15/161 : characterised by the attachment to the sole
• CPC Class Codes: A43D 25/20 : Arrangements for activating or for accelerating setting of adhesives, e.g. by using heat
• CPC Class Codes: A63B 2071/1241 : for the thigh
• CPC Class Codes: A63B 2071/125 : for the knee
• CPC Class Codes: A63B 2071/1258 : for the shin, e.g. shin guards
• CPC Class Codes: A63B 71/1225 : for the legs, e.g. thighs, knees, ankles, feet
• CPC Class Codes: B29D 35/0054 : by compression moulding, vulcanising or the like; Apparatus therefor
• CPC Class Codes: B29D 35/122 : Soles
• CPC Class Codes: B29D 35/124 : Heels
• CPC Class Codes: B29D 35/126 : Uppers
• CPC Class Codes: B29D 35/142 : Soles
• CPC Class Codes: B29K 2105/08 : of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B32B 2260/023 : Two or more layers
• CPC Class Codes: B32B 2260/046 : Synthetic resin
• CPC Class Codes: B32B 2262/02 : Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2262/14 : Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2307/56 : Damping, energy absorption
• CPC Class Codes: B32B 2437/02 : Gloves, shoes
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/12 : characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D05C 17/00 : Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products layered products B32B; non-woven pile fabrics D04H11/00

Abstract

A plate for an article of footwear includes a substrate, a first strand portion attached to the substrate via first stitching, and a second strand portion disposed on the first layer. The first strand portion includes first segments that each extend between two different locations along the substrate to form a first layer on the substrate. The second strand portion includes second segments that each extend between two different locations along the substrate to form a second layer on the first layer.

Claims

1. A method of forming a sole structure for an article of footwear, the method comprising:

positioning a first tow of fibers on a substrate at a first angle relative to a longitudinal axis of the substrate to form a first layer on the substrate;

positioning a second tow of fibers on the first layer at a second angle different than the first angle to form a second layer on the first layer;

positioning a third tow of fibers on the second layer at a third angle different than the second angle to form a third layer on the second layer;

forming the first layer, the second layer, the third layer, and the substrate into plate having an anterior-most point disposed in a forefoot region of the sole structure, a posterior-most point disposed closer to a heel region of the sole structure than the anterior-most point, and a concave portion extending between the anterior-most point and the posterior-most point and including a constant radius of curvature from the anterior-most point to a metatarsophalangeal (MTP) point of the sole structure that opposes the MTP joint of a foot during use; and

providing the plate with a first cushioning layer.

2. The method of claim 1, wherein providing the plate with a first cushioning layer includes providing a cushioning layer at the concave portion of the plate.

3. The method of claim 2, wherein providing the first cushioning layer at the concave portion of the plate includes providing the first cushioning layer between the concave portion and an upper of the article of footwear.

4. The method of claim 1, wherein positioning a third tow of fibers on the second layer at a third angle includes positioning the third tow of fibers at a different angle than the first angle.

5. The method of claim 1, further comprising forming the anterior-most point co-planar with the posterior-most point.

6. The method of claim 1, further comprising providing the plate with a substantially flat portion disposed within a heel region of the sole structure, the posterior-most point being located within the substantially flat portion.

7. The method of claim 6, further comprising providing the plate with a blend portion disposed between the concave portion and the substantially flat portion, the blend portion including a substantially constant curvature.

8. The method of claim 7, wherein providing the plate with a blend portion includes providing the plate with a blend portion having a radius of curvature equal to about 134 millimeters (mm) for a men'"'"'s size ten (10) article of footwear.

9. The method of claim 7, further comprising forming the anterior-most point co-planar with the posterior-most point at a junction of the blend portion and the substantially flat portion.

10. The method of claim 7, further comprising providing a second cushioning layer between the substantially flat portion and at least one of an upper of the article of footwear and a ground-contacting surface of the article of footwear.

11. The method of claim 1, further comprising providing a second cushioning layer between the plate and a ground-contacting surface of the article of footwear, the second cushioning layer disposed on an opposite side of the plate than the first cushioning layer.

12. The method of claim 1, further comprising incorporating the sole structure into an article of footwear.

13. A method of forming a sole structure for an article of footwear, the method comprising:

positioning a first tow of fibers on a substrate at a first angle relative to a longitudinal axis of the substrate to form a first layer on the substrate;

positioning a second tow of fibers on the first layer at a second angle different than the first angle to form a second layer on the first layer;

positioning a third tow of fibers on the second layer at a third angle different than the second angle to form a third layer on the second layer;

forming the first layer, the second layer, the third layer, and the substrate into plate having an anterior-most point disposed in a forefoot region of the sole structure, a posterior-most point disposed closer to a heel region of the sole structure than the anterior-most point, and a curved portion extending between the anterior-most point and the posterior-most point and including a constant radius of curvature from the anterior-most point to a metatarsophalangeal (MTP) point of the sole structure that opposes the MTP joint of a foot during use; and

providing the plate with a first cushioning layer.

14. The method of claim 13, wherein providing the plate with a first cushioning layer includes providing a cushioning layer at the curved portion of the plate.

15. The method of claim 14, wherein providing the first cushioning layer at the curved portion of the plate includes providing the first cushioning layer between the curved portion and an upper of the article of footwear.

16. The method of claim 13, wherein positioning a third tow of fibers on the second layer at a third angle includes positioning the third tow of fibers at a different angle than the first angle.

17. The method of claim 13, further comprising forming the anterior-most point co-planar with the posterior-most point.

18. The method of claim 13, further comprising providing the plate with a substantially flat portion disposed within a heel region of the sole structure, the posterior-most point being located within the substantially flat portion.

19. The method of claim 18, further comprising providing the plate with a blend portion disposed between the curved portion and the substantially flat portion, the blend portion including a substantially constant curvature.

20. The method of claim 19, wherein providing the plate with a blend portion includes providing the plate with a blend portion having a radius of curvature equal to about 134 millimeters (mm) for a men'"'"'s size ten (10) article of footwear.

21. The method of claim 19, further comprising forming the anterior-most point co-planar with the posterior-most point at a junction of the blend portion and the substantially flat portion.

22. The method of claim 19, further comprising providing a second cushioning layer between the substantially flat portion and at least one of an upper of the article of footwear and a ground-contacting surface of the article of footwear.

23. The method of claim 13, further comprising providing a second cushioning layer between the plate and a ground-contacting surface of the article of footwear, the second cushioning layer disposed on an opposite side of the plate than the first cushioning layer.

24. The method of claim 13, further comprising incorporating the sole structure into an article of footwear.