Composite plate for an article of footwear or equipment

• US 10,743,607 B2
• Filed: 02/26/2018
• Issued: 08/18/2020
• 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.
• Primary Examiner(s): Kavanaugh, Ted
• Application Number:
  US15/904,664
• Publication Number:
  US 20180177261A1
• Time in Patent Office: 904 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 5/00 : Footwear for sporting purposes non-skid devices, e.g. ice-spurs or studs for football shoes, A43C15/00
• 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. An upper for an article of footwear, the upper comprising:

a heel counter including a unitary strand having multiple segments of a first tow of fibers that are arranged in parallel to form the heel counter, each segment affixed to a substrate, disposed on an outer surface of the upper, and extending around a portion of the upper; and

a polymeric resin consolidating the first tow of fibers to form the heel counter.

2. The upper of claim 1, wherein each segment of the first tow of fibers defines a length extending between a first end and a second end.

3. The upper of claim 2, wherein the first end of at least one segment of the first tow of fibers is disposed on a medial side of the upper and the second end of the at least one segment of the first tow of fibers is disposed on a lateral side of the upper.

4. The upper of claim 2, wherein the segments of the first tow of fibers include looped portions at the first end and at the second end where adjacent ones of the multiple segments of the first tow of fibers are connected to one another.

5. The upper of claim 1, wherein at least one segment of the multiple segments extends continuously around a heel portion of the upper from a medial side to a lateral side.

6. The upper of claim 1, wherein the heel counter and extends around a heel portion of the upper.

7. The upper of claim 1, wherein the first tow of fibers includes at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.

8. The upper of claim 1, wherein the segments and the substrate are attached to and extend from a plate of the article of footwear.

9. The upper of claim 1, wherein the first tow of fibers is stitched to the substrate via stitching.

10. The upper of claim 9, wherein the first tow of fibers includes first fibers comingled with second fibers, the second fibers including at least one different property than the first fibers.

11. The upper of claim 10, wherein at least one of the stitching, the substrate, the first fibers, and the second fibers comprise a thermoplastic material.

12. An article of footwear including an upper, the article of footwear comprising:

a plate extending along a length of the article of footwear between a heel portion and a forefoot portion;

a heel counter including a unitary strand having multiple segments of a first tow of fibers that are stacked to form the heel counter, the multiple segments extending from the plate and onto an outer surface of the upper; and

a polymeric resin consolidating the first tow of fibers to form the heel counter.

13. The article of footwear of claim 12, wherein the first tow of fibers includes multiple segments, each segment defining a length extending between a first end and a second end.

14. The article of footwear of claim 13, wherein a first end of at least one segment of the first tow of fibers is disposed on a medial side of the upper and a second end of the at least one segment of the first tow of fibers is disposed on a lateral side of the upper.

15. The article of footwear of claim 12, wherein the first tow of fibers is attached to a first substrate.

16. The article of footwear of claim 15, wherein the first substrate is attached to and extends from the plate.

17. The article of footwear of claim 16, wherein the plate is formed from a second tow of fibers that are attached to a second substrate.

18. The article of footwear of claim 17, wherein the first substrate is attached to the second substrate.

19. The article of footwear of claim 17, wherein the first substrate and the second substrate are part of the same unitary substrate.

20. The article of footwear of claim 12, wherein the first tow of fibers extends around and from a peripheral edge of the plate.

21. The article of footwear of claim 20, wherein the peripheral edge is disposed at the heel portion of the plate.

22. The article of footwear of claim 12, wherein the first tow of fibers includes at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.

23. The article of footwear of claim 12, wherein the first tow of fibers is stitched to a substrate via stitching.

24. The article of footwear of claim 23, wherein the first tow of fibers includes first fibers comingled with second fibers, the second fibers including at least one different property than the first fibers.

25. The article of footwear of claim 24, wherein at least one of the stitching, the substrate, the first fibers, and the second fibers comprise a thermoplastic material.