Composite sole structure

• US 9,549,589 B2
• Filed: 03/26/2014
• Issued: 01/24/2017
• Est. Priority Date: 01/19/2011
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Auger, Perry W., Caine, Andrew, Cavaliere, Sergio
• Primary Examiner(s): BAYS, MARIE D
• Application Number:
  US14/225,643
• Publication Number:
  US 20140331418A1
• Time in Patent Office: 1,035 Days
• Field of Search: 36/91, 36/30.R, 361/07, 361/08, 36/76.R, 36/76.C
• US Class Current: 1/1
• CPC Class Codes: A43B 1/0009 made at least partially of alveolar or honeycomb material
• 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 13/12 Soles with several layers of different materials
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/141 with a part of the sole being flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 13/26 projecting beyond the sole surface
• CPC Class Codes: A43B 5/02 Football boots or shoes, i.e. for soccer, football or rugby
• CPC Class Codes: A43C 15/02 attached to the sole
• CPC Class Codes: A43D 29/00 Machines for making soles from strips of material

Abstract

Embodiments relating to a lightweight sole structure are disclosed. In some embodiments, the sole structure may include a lobed member having a protruding portion associated with a cleat member. In some embodiments, the sole structure may include a chambered member located in an indention in an intermediate member. In some embodiments, the sole structure may include a cleat member having an outer layer, an intermediate layer, and an inner layer. In some embodiments, a method of making a sole structure may include injecting a chambered member in between an upper member and an intermediate member. In some embodiments, the sole structure may include a plurality of zones having varying degrees of flexibility. In some embodiments, the sole structure may include cleat members having penetrating portions for penetrating into the ground surface.

Claims

1. A method of making a sole structure, comprising:

forming an upper plate member, wherein the upper plate member has a top surface, and a bottom surface;

forming an intermediate plate member, wherein the intermediate plate member has a top surface and a bottom surface, wherein the top surface of the intermediate plate member includes a concave indentation;

placing the top surface of the intermediate plate member in contact with the bottom surface of the upper plate member; and

incorporating a chambered member into the indentation of the intermediate plate member, wherein the chambered member has honeycomb volume; and

wherein the chambered member is formed of a substantially rigid material.

2. The method of claim 1, wherein the indentation and the chambered member are Y-shaped.

3. The method of claim 1, further including bonding the intermediate plate member, the upper plate member and the chambered member together using a heat press.

4. The method of claim 1, further including bonding the intermediate plate member, the upper plate member and the chambered member together using thermoplastic polyurethane.

5. The method of claim 1, further including forming the intermediate plate member from a carbon composite.

6. The method of claim 1, further including forming the upper plate member from a glass composite.

7. The method of claim 1, wherein incorporating the chambered member into the indentation of the intermediate member includes injection molding the chambered member within the indentation in the intermediate member and wherein the step of injection molding the chambered member within the indentation in the intermediate member occurs before the step of placing the top surface of the intermediate plate member in contact with the bottom surface of the upper plate member.

8. The method of claim 1, wherein the intermediate member is formed of a substantially rigid material.

9. The method of claim 1, further including forming the upper plate member with a first length, and forming the intermediate plate member with a second length, wherein the first length is greater than the second length.

10. The method of claim 1, wherein the chambered member extends from a heel region through a midfoot region of the sole structure.

11. The method of claim 1, wherein the top surface of the chambered member is flush with the top surface of the intermediate member.