COMPOSITE PLATE FOR AN ARTICLE OF FOOTWEAR OR EQUIPMENT

• US 20190059510A1
• Filed: 07/20/2017
• Published: 02/28/2019
• Est. Priority Date: 07/20/2016
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Amis, Sam, Bartel, Aaron, Guest, Stefan E., Lacey, Sam, McFarland, II, William C., Steinbeck, Christian Alexander, Sterman, Yoav, Thuss, Adam, Waatti, Todd A.
• Granted Patent: US 10,349,700 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 method for forming a plate includes attaching a first strand portion to a flexible substrate to form a first layer on the substrate and positioning a second strand portion on the first layer to form a second layer on the first layer in a plurality of discrete regions on the substrate. The method also includes positioning a plurality of traction elements into corresponding cavities formed into a first mold surface and positioning the substrate on the first mold surface to change a shape of the substrate. At least one of heat and pressure is applied to the first strand portion, the second strand portion, the substrate, and the traction elements to conform the substrate to the shape of the first mold surface and form the traction elements into the substrate at each of the discrete regions. The method also includes incorporating the substrate into an article of footwear.

Claims

1. A method of forming an article of footwear, the method comprising:

attaching a first strand portion to a flexible substrate to form a first layer on the substrate;

positioning a second strand portion on the first layer to form a second layer on the first layer in a plurality of discrete regions on the substrate;

positioning the substrate on a first mold surface to change a shape of the substrate;

applying at least one of heat and pressure to the first strand portion, the second strand portion, and the substrate to conform the substrate to the shape of the first mold surface and to form traction elements from the second strand portion at each of the discrete regions; and

incorporating the substrate into an article of footwear.

2. The method of claim 1, wherein positioning the substrate on the first mold surface includes aligning cavities formed into the first mold surface with the discrete regions of the substrate.

3. The method of claim 1, wherein attaching the first strand portion to the flexible substrate includes attaching the first strand portion to the flexible substrate via first stitching that crosses over the first strand portion and penetrates the substrate at first attachment locations that are spaced apart from the first strand portion.

4. The method of claim 1, wherein positioning the second strand portion on the first layer includes attaching the first strand portion to the flexible substrate via second stitching that crosses over the second strand portion, extends through the first strand portion, and penetrates the substrate at second attachment locations disposed in the discrete regions of the substrate.

5. The method of claim 1, further comprising forming the second strand portion from a plurality of different strands of fibers each corresponding to one of the discrete regions.

6. The method of claim 1, further comprising forming at least one of the first strand portion and the second strand portion of the same, continuous strand.

7. The method of claim 1, further comprising forming the first strand portion from a first tow of fibers including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.

8. The method of claim 1, further comprising forming the second strand portion from a second tow of fibers including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.

9. The method of claim 1, further comprising:

providing the first strand portion with looped portions disposed proximate to a peripheral edge of the substrate, the looped portions connecting adjacent first segments; and

removing at least one of the looped portions that extends outside the peripheral edge of the substrate.

10. The method of claim 1, further comprising providing the first layer and the second layer with segments having different densities.

11. The method of claim 1, wherein attaching the first strand portion includes applying first segments of the first strand portion to the substrate in a first shape and positioning the second strand portion includes applying second segments of the second strand portion to the first layer in a second shape different than the first shape.

12. The method of claim 1, wherein applying at least one of heat and pressure includes at least one of activating a polymeric resin incorporated into the first strand portion and the second strand portion and infusing the first strand portion, the second strand portion, and the substrate with a liquid material, the liquid material being a thermoset material.

13. The method of claim 1, wherein applying at least one of heat and pressure includes subjecting the first strand portion, the second strand portion, and the substrate to at least one of vacuum molding and compression molding.

14. The method of claim 1, further comprising forming the substrate from a thermoplastic film.

15. The method of claim 1, wherein incorporating the substrate into the article of footwear includes attaching the substrate to an upper of the article of footwear.

16. The method of claim 1, further comprising positioning a third strand portion on the substrate between the traction elements.

17. The method of claim 16, wherein positioning a third strand portion on the substrate between the traction elements includes wrapping the third strand portion around the traction elements.

18. The method of claim 1, further comprising positioning a plurality of traction element tips into corresponding cavities formed into the first mold surface and wherein applying at least one of heat and pressure to the first strand portion, the second strand portion, and the substrate comprises applying at least one of heat and pressure to the first strand portion, the second strand portion, the substrate, and the traction element tips.

19. The method of claim 18, further comprising attaching the traction element tips to respective ones of the traction elements.