Footwear plate

• US 10,798,992 B2
• Filed: 07/20/2017
• Issued: 10/13/2020
• Est. Priority Date: 07/20/2016
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Bartel, Aaron, Guest, Stefan E., Haight, Derek, Kiss, Adam, Lacey, Sam, Luo, Geng, Savage, Rachel M., Steinbeck, Christian Alexander, Thuss, Adam
• Primary Examiner(s): Bays, Marie D
• Application Number:
  US16/318,735
• Publication Number:
  US 20190283355A1
• Time in Patent Office: 1,181 Days
• Field of Search: 12142 R, 12146 R, 12146 S
• 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 of forming a plate for an article of footwear is disclosed. The method includes applying a first strand portion to a base layer including positioning adjacent segments of the first strand portion to form a first layer on the base layer. The adjacent segments of the first strand portion having a greater density across a width of the plate between a medial side and a lateral side at a forefoot region of the plate than at a midfoot region of the plate and at a heel region of the plate. The method also includes applying at least one of heat and pressure to the first strand portion and to the base layer to conform the first strand portion and the base layer to a predetermined shape.

Claims

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

applying a first strand portion to a base layer including positioning adjacent segments of the first strand portion to form a first layer on the base layer, the adjacent segments of the first strand portion having a greater density across a width of the plate between a medial side and a lateral side at a forefoot region of the plate than at a midfoot region of the plate and at a heel region of the plate;

attaching the first strand portion to the base layer using stitching; and

applying at least one of heat and pressure to the first strand portion and to the base layer to conform the first strand portion and the base layer to a predetermined shape.

2. The method of claim 1, wherein applying the first strand portion to the base layer includes forming loops that connect adjacent segments of the first strand portion.

3. The method of claim 1, wherein applying the first strand portion to the base layer includes applying the first strand portion to at least one of a substrate and a second layer having a plurality of fibers and/or to a second layer formed from unidirectional tape.

4. The method of claim 1, further comprising positioning a second strand portion on the first layer to form a second layer on the first layer.

5. The method of claim 4, wherein attaching the first strand portion to the base layer using stitching includes applying first stitching that crosses over the first strand portion and penetrates the base layer at first attachment locations that are spaced apart from the first strand portion and positioning the second strand portion on the first layer includes applying second stitching that crosses over the second strand portion, extends through the first strand portion, and penetrates the base layer at second attachment locations.

6. The method of claim 1, wherein applying the first strand portion to a base layer includes positioning adjacent segments closer to one another across the width of the plate between the medial side and the lateral side at the forefoot region of the plate than at the midfoot region of the plate and at the heel region of the plate.

7. The method of claim 1, wherein applying the first strand portion to the base layer includes positioning first segments of the first strand portion on the base layer in a first shape and positioning second segments of the first strand portion on the base layer in a second shape different than the first shape, the second segments being convergent with the first segments and disposed adjacent and substantially parallel with one another.

8. The method of claim 7, wherein applying the first strand portion to the base layer further includes positioning third segments of the first strand portion on the base layer in a third shape different than the first shape and the second shape, the third segments being convergent with the first segments and the second segments and disposed adjacent and substantially parallel with one another.

9. The method of claim 8, wherein positioning the first segments of the first strand portion on the base layer includes positioning the first segments of the first strand portion on the base layer with each first segment having a corresponding length that extends between a corresponding first end proximate to a toe end of the plate and a corresponding second end proximate to the medial side of the plate in the forefoot region, and positioning the second segments of the first strand portion on the base layer includes positioning the second segments of the first strand portion on the base layer with each second segment having a corresponding length that extends between a corresponding first end proximate to the lateral side of the plate in the forefoot region and a corresponding second end proximate to the medial side of the plate in the midfoot region, and positioning the third segments of the first strand portion on the base layer includes positioning the third segments of the first strand portion on the base layer with each third segment having a corresponding length that extends between a corresponding first end proximate to the lateral side of the plate in the midfoot region and a corresponding second end proximate to a heel end of the plate.

10. The method of claim 7, wherein positioning the first segments of the first strand portion on the base layer includes positioning the first segments of the first strand portion on the base layer with each first segment having a corresponding length that extends between a corresponding first end proximate to the lateral side of the plate in the forefoot region and a corresponding second end proximate to the medial side of the plate in the forefoot region, and positioning the second segments of the first strand portion on the base layer includes positioning the second segments of the first strand portion on the base layer with each second segment having a corresponding length that extends between a corresponding first end proximate to the lateral side of the plate in a corresponding one of the midfoot region and the heel region and a corresponding second end proximate to the medial side of the plate in the corresponding one of the midfoot region and the heel region.

11. 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.

12. The method of claim 1, further comprising consolidating fibers of the first strand portion with a polymeric resin during the application of heat and/or pressure, the polymeric resin being a thermoset resin or a thermoplastic resin.

13. The method of claim 1, wherein forming the plate includes forming the plate with a stiffness in the forefoot region along a baseline of the plate from a heel end of the plate to a toe end of the plate of about 350 N/mm to about 500 N/mm, a stiffness in the forefoot region across a width of the plate from the medial side to the lateral side of about 150 N/mm to about 300 N/mm, and a stiffness in the midfoot region across the width of the plate from the medial side to the lateral side of about 150 N/mm to about 300 N/mm.

14. The method of claim 1, wherein forming the plate includes forming the plate with a stiffness in the forefoot region along a baseline of the plate from a heel end of the plate to a toe end of the plate of about 375 N/mm to about 475 N/mm, a stiffness in the forefoot region across a width of the plate from the medial side to the lateral side of about 200 N/mm to about 300 N/mm, and a stiffness in the midfoot region across the width of the plate from the medial side to the lateral side of about 150 N/mm to about 250 N/mm.

15. The method of claim 1, wherein forming the plate includes forming the plate with a stiffness in the forefoot region along a baseline of the plate from a heel end of the plate to a toe end of the plate of about 400 N/mm to about 450 N/mm, a stiffness in the forefoot region across a width of the plate from the medial side to the lateral side of about 225 N/mm to about 275 N/mm, and a stiffness in the midfoot region across the width of the plate from the medial side to the lateral side of about 175 N/mm to about 225 N/mm.

16. The method of claim 2, further comprising removing the loops of the first strand portion to define an outer edge of the plate.

17. The method of claim 2, wherein applying the first strand portion to the base layer includes applying a continuous strand to the base layer.