Article of Footwear Having a Sole Plate

This patent application is a divisional of U.S. patent application Ser. No. 18/229,097, filed Aug. 1, 2023, which is a continuation of U.S. patent application Ser. No. 18/114,670, filed Feb. 27, 2023, and U.S. patent application Ser. No. 17/992,397, filed Nov. 22, 2022, which are continuations of U.S. patent application Ser. No. 17/404,388, filed Aug. 17, 2021, which claims the benefit of U.S. Provisional Patent Application 63/067,073, filed on Aug. 18, 2020, the entire contents of which is hereby incorporated by reference, for any and all purposes.

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The present disclosure relates generally to an article of footwear including a sole plate.

Many conventional shoes or other articles of footwear generally comprise an upper and a sole attached to a lower end of the upper. Conventional shoes further include an internal space, i.e., a void or cavity, which is created by interior surfaces of the upper and sole, that receives a foot of a user before securing the shoe to the foot. The sole attaches to a lower surface or boundary of the upper and positions itself between the upper and the ground. As a result, the sole typically provides stability and cushioning to the user when the shoe is being worn. In some instances, the sole may include multiple components, such as an outsole, a midsole, and an insole. The outsole may provide traction to a bottom surface of the sole, and the midsole may be attached to an inner surface of the outsole, and may provide cushioning or added stability to the sole. For example, a sole may include a particular foam material that may increase stability at one or more desired locations along the sole, or a foam material that may reduce stress or impact energy on the foot or leg when a user is running, walking, or engaged in another activity. The sole may also include additional components, such as plates, embedded with the sole to increase the overall stiffness of the sole and reduce energy loss during use.

The upper generally extends upward from the sole and defines an interior cavity that completely or partially encases a foot. In most cases, the upper extends over the instep and toe regions of the foot, and across medial and lateral sides thereof. Many articles of footwear may also include a tongue that extends across the instep region to bridge a gap between edges of medial and lateral sides of the upper, which define an opening into the cavity. The tongue may also be disposed below a lacing system and between medial and lateral sides of the upper, to allow for adjustment of shoe tightness. The tongue may further be manipulable by a user to permit entry or exit of a foot from the internal space or cavity. In addition, the lacing system may allow a user to adjust certain dimensions of the upper or the sole, thereby allowing the upper to accommodate a wide variety of foot types having varying sizes and shapes.

The upper of many shoes may comprise a wide variety of materials, which may be utilized to form the upper and chosen for use based on one or more intended uses of the shoe. The upper may also include portions comprising varying materials specific to a particular area of the upper. For example, added stability may be desirable at a front of the upper or adjacent a heel region so as to provide a higher degree of resistance or rigidity. In contrast, other portions of a shoe may include a soft woven textile to provide an area with stretch-resistance, flexibility, air-permeability, or moisture-wicking properties.

However, in many cases, articles of footwear having uppers with an increased comfort and better fit are desired, along with soles having improved cushioning systems or structural characteristics such as a sole plate to add rigidity or spring-like properties.

An article of footwear, as described herein, may have various configurations. The article of footwear may have an upper and a sole structure connected to the upper.

In some aspects, an article of footwear can define a lateral side, a medial side, a forefoot region, a midfoot region, and a heel region. The article of footwear can include an upper, a first cushioning member directly coupled to the upper in the heel region, and a second cushioning member directly coupled to the upper in the forefoot region. The article of footwear can also include a plate configured as a unitary plate that extends continuously from the forefoot region to the heel region. The plate can be directly coupled to each of the upper, the first cushioning member, and the second cushioning member, and can extend through a gap that is defined between the first cushioning member and the second cushioning member.

In some examples, the plate can include an anterior curved portion that is directly coupled to the second cushioning member, a substantially planar portion that is directly coupled to the first cushioning member, and a posterior curved portion that extends between the anterior curved portion and the posterior curved portion.

In some examples, the posterior curved portion can be positioned in the gap.

In some examples, the first cushioning member, the second cushioning member, and the sole plate can define a sole structure of the article of footwear, and the second cushioning member can define a heelmost end of the sole structure.

In some examples, the first cushioning member can be entirely spaced apart from the second cushioning member by the gap.

In some examples, the article of footwear can further include an outsole coupled to the first cushioning member.

In some examples, a toemost end of the first cushioning member can be in the forefoot region and a heelmost end of the first cushioning member can be in the midfoot region, and a toemost end of the second cushioning member can be in the midfoot region and a heelmost end of the second cushioning member can be in the heel region.

In some examples, the plate can be visible when the article of footwear is viewed from both the lateral side and the medial side.

In some examples, the toemost end of the second cushioning member can overlap the heelmost end of the first cushioning member such that the toemost end of the second cushioning is above the heelmost end of the first cushioning member when the article of footwear is viewed from the lateral side.

In some examples, the toemost end of the second cushioning member can overlap the heelmost end of the first cushioning member such that the toemost end of the second cushioning is above the heelmost end of the first cushioning member when the article of footwear is viewed from the medial side.

In some aspects, an article of footwear can define a lateral side, a medial side, a forefoot region defining a toe end, a midfoot region, and a heel region defining a heel end. The article of footwear can include an upper and a sole structure coupled to the upper and defining a ground-engaging surface of the article of footwear. The sole structure can include a first cushioning member directly coupled to the upper in the heel region, where a toemost end of the first cushioning member can be in the midfoot region and a heelmost end of the first cushioning member can define a heelmost end of the sole structure. The sole structure can also include a second cushioning member directly coupled to the upper in the forefoot region, where a toemost end of the second cushioning member can be in the forefoot region and a heelmost end of the second cushioning member can be in the midfoot region. The sole structure can further include a plate configured as a unitary plate that extends continuously from the forefoot region to the heel region, the plate extending through a gap that is defined between the first cushioning member and the second cushioning member, and the plate being visible when the article of footwear is viewed from both the lateral side and the medial side. The sole structure can also include an outsole coupled to the second cushioning member, the outsole extending from a first end positioned in the forefoot region to a second end positioned in the midfoot region.

In some examples, the plate can be visible when the article of footwear is viewed from a bottom of the article of footwear.

In some examples, the plate can include a substantially planar portion that is coupled to the first cushioning member and a curved portion that extends through the gap.

In some examples, the curved portion can include a posterior curved portion that extends from the substantially planar portion and into the gap, and an anterior curved portion that extends from the posterior curved portion and that is coupled to the second cushioning member.

In some examples, the plate can define a protrusion that extends away from the upper.

In some examples, the protrusion can be positioned in the gap.

In some examples, the plate can comprise a thermoplastic polymer.

In some examples, the plate can be spaced from the upper at the gap so that there is an absence of material of the sole structure between the plate and the upper.

In some aspects, an article of footwear can define a lateral side, a medial side, a forefoot region defining a toe end, a midfoot region, and a heel region defining a heel end. The article of footwear can include an upper and a sole structure coupled to the upper and defining a ground-engaging surface of the article of footwear. The sole structure can include a first cushioning member directly coupled to the upper in the heel region, where a toemost end of the first cushioning member can be in the midfoot region and a heelmost end of the first cushioning member can define a heelmost end of the sole structure. The sole structure can also include a second cushioning member directly coupled to the upper in the forefoot region, where a toemost end of the second cushioning member can be in the forefoot region and a heelmost end of the second cushioning member can be in the midfoot region. The sole structure can further include a plate configured as a unitary plate that includes a substantially planar portion coupled to the first cushioning member, an anterior curved portion coupled to the second cushioning member, and a posterior curved portion extending between the substantially planar portion and the anterior curved portion, the posterior curved portion positioned in a gap that is defined between the first cushioning member and the second cushioning member.

Other aspects of the article of footwear, including features and advantages thereof, will become apparent to one of ordinary skill in the art upon examination of the figures and detailed description herein. Therefore, all such aspects of the article of footwear are intended to be included in the detailed description and this summary.

The following discussion and accompanying figures disclose various embodiments or configurations of a shoe and a sole structure. Although embodiments of a shoe or sole structure are disclosed with reference to a sports shoe, such as a running shoe, tennis shoe, basketball shoe, etc., concepts associated with embodiments of the shoe or the sole structure may be applied to a wide range of footwear and footwear styles, including cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and cleats, walking shoes, and track cleats, for example. Concepts of the shoe or the sole structure may also be applied to articles of footwear that are considered non-athletic, including dress shoes, sandals, loafers, slippers, and heels. In addition to footwear, particular concepts described herein may also be applied and incorporated in other types of apparel or other athletic equipment, including helmets, padding or protective pads, shin guards, and gloves. Even further, particular concepts described herein may be incorporated in cushions, backpack straps, golf clubs, or other consumer or industrial products. Accordingly, concepts described herein may be utilized in a variety of products.

The term “about,” as used herein, refers to variation in the numerical quantity that may occur, for example, through typical measuring and manufacturing procedures used for articles of footwear or other articles of manufacture that may include embodiments of the disclosure herein; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients used to make the compositions or mixtures or carry out the methods; and the like. Throughout the disclosure, the terms “about” and “approximately” refer to a range of values ±5% of the numeric value that the term precedes.

The terms “weight percent,” “wt-%,” “percent by weight,” “% by weight,” and variations thereof, as used herein, refer to the concentration of a substance or component as the weight of that substance or component divided by the total weight, for example, of the composition or of a particular component of the composition, and multiplied by. It is understood that, as used herein, “percent,” “%,” and the like may be synonymous with “weight percent” and “wt-%.”

The present disclosure is directed to an article of footwear and/or specific components of the article of footwear, such as an upper and/or a sole or sole structure. The upper may comprise a knitted component, a woven textile, and/or a non-woven textile. The knitted component may be made by knitting of yarn, the woven textile by weaving of yarn, and the non-woven textile by manufacture of a unitary non-woven web. Knitted textiles include textiles formed by way of warp knitting, weft knitting, flat knitting, circular knitting, and/or other suitable knitting operations. The knit textile may have a plain knit structure, a mesh knit structure, and/or a rib knit structure, for example. Woven textiles include, but are not limited to, textiles formed by way of any of the numerous weave forms, such as plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weaves, and/or double cloth weaves, for example. Non-woven textiles include textiles made by air-laid and/or spun-laid methods, for example. The upper may comprise a variety of materials, such as a first yarn, a second yarn, and/or a third yarn, which may have varying properties or varying visual characteristics.

depict an exemplary embodiment of an article of footwearincluding an upperand a sole structure. The upperis attached to the sole structureand together define an interior cavity into which a foot may be inserted. For reference, the article of footweardefines a forefoot region, a midfoot region, and a heel region. The forefoot regiongenerally corresponds with portions of the article of footwearthat encase portions of the foot that includes the toes, the ball of the foot, and joints connecting the metatarsals with the toes or phalanges. The midfoot regionis proximate and adjoining the forefoot region, and generally corresponds with portions of the article of footwearthat encase the arch of foot, along with the bridge of the foot. The heel regionis proximate and adjoining the midfoot regionand generally corresponds with portions of the article of footwearthat encase rear portions of the foot, including the heel or calcaneus bone, the ankle, and/or the Achilles tendon.

Many conventional footwear uppers are formed from multiple elements (e.g., textiles, polymer foam, polymer sheets, leather, and synthetic leather) that are joined through bonding or stitching at a seam. In some embodiments, the upperof the article of footwearis formed from a knitted structure or knitted components. In various embodiments, a knitted component may incorporate various types of yarn that may provide different properties to an upper. For example, one area of the uppermay be formed from a first type of yarn that imparts a first set of properties, and another area of the uppermay be formed from a second type of yarn that imparts a second set of properties. Using this configuration, properties of the uppermay vary throughout the upperby selecting specific yarns for different areas of the upper.

The article of footwearalso includes a medial side(e.g., see) and a lateral side(e.g., see). In particular, the lateral sidecorresponds to an outside portion of the article of footwearand the medial sidecorresponds to an inside portion of the article of footwear. As such, left and right articles of footwear have opposing lateral and medial sides, such that the medial sidesare closest to one another when a user is wearing the articles of footwear, while the lateral sidesare defined as the sides that are farthest from one another while being worn. The medial sideand the lateral sideadjoin one another at opposing, distal ends of the article of footwear.

Unless otherwise specified, the forefoot region, the midfoot region, the heel region, the medial side, and the lateral sideare intended to define boundaries or areas of the article of footwear. To that end, the forefoot region, the midfoot region, the heel region, the medial side, and the lateral sidegenerally characterize sections of the article of footwear. Further, both the upperand the sole structuremay be characterized as having portions within the forefoot region, the midfoot region, the heel region, and on the medial sideand the lateral side. Therefore, the upperand the sole structure, and/or individual portions of the upperand the sole structure, may include portions thereof that are disposed within the forefoot region, the midfoot region, the heel region, and on the medial sideand the lateral side.

The sole structureis connected or secured to the upperand extends between a foot of a user and the ground when the article of footwearis worn by the user. The sole structuremay include one or more components, which may include an outsole, a midsole, a heel, a vamp, and/or an insole. For example, in some embodiments, a sole structure may include an outsole that provides structural integrity to the sole structure, along with providing traction for a user, a midsole that provides a cushioning system, and an insole that provides support for an arch of a user. As will be further discussed herein, the sole structureof the present embodiment of the invention includes one or more components that provide the sole structurewith preferable spring and damping properties.

The sole structureincludes an outsole, a first cushioning member, a second cushioning member, and a sole plate(see). The outsolemay define a bottom end or surface of the sole structureacross the heel region, the midfoot region, and the forefoot region. Further, the outsolemay be a ground-engaging portion or include a ground-engaging surface of the sole structureand may be opposite of the insole thereof. The outsolemay be formed from one or more materials to impart durability, wear-resistance, abrasion resistance, or traction to the sole structure. In some embodiments, the outsolemay be formed from rubber, for example.

The first cushioning membermay be positioned adjacent to and on top of the outsolein the heel region, and positioned adjacent to and on top of the second cushioning memberin the midfoot regionand forefoot region. The first cushioning membermay include one or more longitudinal grooves or flex linesthat extend between the medial sideand the lateral side, which segments the first cushioning memberin the heel region. For example, in the particular embodiment shown in, the first cushioning memberincludes five flex lines, which define four flex regions. Further, as best shown in, the flex linesmay have a sinusoidal shape between the medial sideand the lateral side.

The second cushioning membermay be positioned adjacent to and on top of the outsolein the midfoot regionand forefoot region. As will be further discussed herein, the second cushioning membermay also be positioned between or be enclosed within the sole platein the midfoot regionand/or the forefoot region(see).

The first cushioning memberand/or the second cushioning membermay be individually constructed from a thermoplastic material, such as polyurethane (PU), for example, and/or an ethylene-vinyl acetate (EVA), copolymers thereof, or a similar type of material. In other embodiments, the first cushioning memberand/or the second cushioning membermay be an EVA-Solid-Sponge (“ESS”) material, an EVA foam (e.g., PUMA® ProFoam Lite™, IGNITE Foam), polyurethane, polyether, an olefin block copolymer, a thermoplastic material (e.g., a thermoplastic polyurethane, a thermoplastic elastomer, a thermoplastic polyolefin, etc.), or a supercritical foam. The first cushioning memberand/or the second cushioning membermay be a single polymeric material or may be a blend of materials, such as an EVA copolymer, a thermoplastic polyurethane, a polyether block amide (PEBA) copolymer, and/or an olefin block copolymer. One example of a PEBA material is PEBAX®.

In embodiments where the first cushioning memberand/or the second cushioning memberis formed from a supercritical foaming process, the supercritical foam may comprise micropore foams or particle foams, such as a TPU, EVA, PEBAX®, or mixtures thereof, manufactured using a process that is performed within an autoclave, an injection molding apparatus, or any sufficiently heated/pressurized container that can process the mixing of a supercritical fluid (e.g., CO, N, or mixtures thereof) with a material (e.g., TPU, EVA, polyolefin elastomer, or mixtures thereof) that is preferably molten. During an exemplary process, a solution of supercritical fluid and molten material is pumped into a pressurized container, after which the pressure within the container is released, such that the molecules of the supercritical fluid rapidly convert to gas to form small pockets within the material and cause the material to expand into a foam, which may be used as the first cushioning memberand, more preferably, the second cushioning member. In further embodiments, the first cushioning memberand/or the second cushioning membermay be formed using alternative methods known in the art, including the use of an expansion press, an injection machine, a pellet expansion process, a cold foaming process, a compression molding technique, die cutting, or any combination thereof. For example, the first cushioning memberand/or the second cushioning membermay be formed using a process that involves an initial foaming step in which supercritical gas is used to foam a material and then compression molded or die cut to a particular shape.

The sole structurefurther includes the sole plate, which as best shown in, includes an upper flangeand a lower flangeand an arched, curved, or C-shaped rear portionthat connects the upper flangeand the lower flange. Further, a gapextends between the upper flangeand the lower flange, into which the second cushioning membermay be positioned, as previously discussed herein. As shown in, the sole plateextends at least partially through the midfoot regionand at least partially through the forefoot region. As further illustrated in, the rear portionof the sole platemay be spaced from a rear side of the second cushioning member, which creates a spacingtherebetween.

With continued reference to, the lower flangemay be adjacent to and positioned between the outsoleand the second cushioning member, and the upper flangemay be adjacent to and positioned between the second cushioning memberand the first cushioning member. In some embodiments, the sole platehas a uniform thickness. For example, in particular embodiments, the thickness is approximately 1.2 centimeters.

In some embodiments, the sole platecomprises a PU plastic, such as a thermoplastic polyurethane (TPU) material, for example. Other thermoplastic elastomers consisting of block copolymers are also possible. In other embodiments, the sole platecan include carbon fiber, for example.

In some embodiments, the outsoleor the ground-engaging surface is not continuous along the article of footwear. For example, as best shown in, there is a spacing, or an absence of a ground-engaging surface, along the article of footwear, which is located within the midfoot regionof the article of footwear.

show another configuration of an article of footwear. Similar to the sole structure, the sole structureis configured to be attached to an upperand together define an interior cavity into which a foot may be inserted. For reference, the sole structuredefines a forefoot region, a midfoot region, and a heel region. The forefoot regiongenerally corresponds with portions of an article of footwear, such as the article of footwear, for example, that encase portions of the foot that include the toes, the ball of the foot, and joints connecting the metatarsals with the toes or phalanges. The midfoot regionis proximate and adjoining the forefoot region, and generally corresponds with portions of the article of footwear that encase the arch of a foot, along with the bridge of a foot. The heel regionis proximate and adjoining the midfoot regionand generally corresponds with portions of the article of footwear that encase rear portions of the foot, including the heel or calcaneus bone, the ankle, and/or the Achilles tendon.

The article of footwearalso includes a medial side(e.g., see) and a lateral side(e.g., see). In particular, the lateral sidecorresponds to an outside portion of the article of footwearand the medial sidecorresponds to an inside portion of the article of footwear. As such, left and right articles of footwear have opposing lateral and medial sides, such that the medial sidesare closest to one another when a user is wearing the articles of footwear, while the lateral sidesare defined as the sides that are farthest from one another while being worn. The medial sideand the lateral sideadjoin one another at opposing, distal ends of the article of footwear.

Unless otherwise specified, the forefoot region, the midfoot region, the heel region, the medial side, and the lateral sideare intended to define boundaries or areas of the article of footwear. To that end, the forefoot region, the midfoot region, the heel region, the medial side, and the lateral sidegenerally characterize sections of the article of footwear. Further, both the upperand the sole structuremay be characterized as having portions within the forefoot region, the midfoot region, the heel region, and on the medial sideand the lateral side. Therefore, the upperand the sole structure, and/or individual portions of the upperand the sole structure, may include portions thereof that are disposed within the forefoot region, the midfoot region, the heel region, and on the medial sideand the lateral side.