Article of footwear including full length composite plate
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
A43B-013/02
A43B-013/12
A43B-013/14
B29D-035/14
A43D-008/00
출원번호
US-0330103
(2014-07-14)
등록번호
US-10016012
(2018-07-10)
발명자
/ 주소
Auger, Perry W.
Krstic, Ruzica
Stone, N. Spencer
Wachtel, Edward F.
출원인 / 주소
NIKE, Inc.
대리인 / 주소
Honigman Miller Schwartz and Cohn LLP
인용정보
피인용 횟수 :
0인용 특허 :
74
초록▼
A full length composite plate to be used as part of an outsole assembly in an article of footwear is disclosed. The full length composite plate comprises a composite material that has a certain percent elongation. The full length composite plate can include a heel cup for heel stability and improved
A full length composite plate to be used as part of an outsole assembly in an article of footwear is disclosed. The full length composite plate comprises a composite material that has a certain percent elongation. The full length composite plate can include a heel cup for heel stability and improved traction. The full length composite plate also can include two angled portions along an arch region that provide arch support, as well as two flattened edges along the arch region to minimize or eliminate buckling. The forefoot region can be relatively flatter than the arch and heel regions, and notches are preferably included along a portion of the forefoot to increase flexibility.
대표청구항▼
1. A method of making an article of footwear comprising: positioning a full length composite plate between a molding base and a mold, the composite plate including a first side in opposed contact with a support surface of the molding base, a second side disposed on an opposite side of the composite
1. A method of making an article of footwear comprising: positioning a full length composite plate between a molding base and a mold, the composite plate including a first side in opposed contact with a support surface of the molding base, a second side disposed on an opposite side of the composite plate than the first side and opposing a mold surface of the mold, and a continuous and arcuate perimeter edge bounding an uninterrupted surface extending continuously from a heel end of the composite plate to a forefoot end of the composite plate and from a lateral side to a medial side of the article of footwear;moving at least one of the mold and the molding base toward the other of the mold and the molding base to enclose the composite plate within a cavity of the mold;filling the cavity with a liquid or viscous substance to cover the second side of the composite plate; andsolidifying the liquid or viscous substance to form a molding attached to the second side of the composite plate. 2. The method according to claim 1, wherein the cavity contains at least one secondary cavity disposed along, and in fluid communication with, an outer periphery of the cavity. 3. The method according to claim 2, further comprising filling the at least one secondary cavity with the liquid or viscous substance to form a traction element. 4. The method according to claim 1, further comprising holding the mold against the molding base under enough pressure to keep the liquid or viscous substance confined to a region bounded by the cavity and a portion of the molding base exposed to the cavity. 5. The method according to claim 1, wherein a cavity rim defining an outer periphery of the cavity and disposed along the mold surface of the mold has a perimeter larger than a perimeter of the composite plate. 6. The method according to claim 1, further comprising filling the cavity with the liquid or viscous substance through one or more injection channels of the mold. 7. The method according to claim 1, wherein the mold surface of the mold contacts the support surface of the molding base at a location spaced apart from a perimeter edge of the composite plate, wherein a portion of the support surface of the molding base is exposed to the cavity between the perimeter edge of the composite plate and a cavity rim defining an outer periphery of the cavity. 8. The method according to claim 7, wherein the portion of the support surface of the molding base that is exposed to the cavity is in contact with the liquid or viscous substance such that the liquid or viscous substance is disposed flush with the first side of the composite plate. 9. The method according to claim 7, wherein filling the cavity with the liquid or viscous substance comprises encasing at least one edge of the composite plate with the liquid or viscous substance. 10. The method according to claim 9, wherein the at least one edge comprises at least one of a lateral edge and a medial edge of an arch region of the composite plate. 11. The method according to claim 1, wherein positioning the full length composite plate between the molding base and the mold includes mating non-flat features of the composite plate with corresponding non-flat features of the support surface of the molding base. 12. The method according to claim 1, wherein an angled portion of the mold is disposed adjacent to a corresponding angled portion of the second side of the composite plate when the composite plate is enclosed within the cavity. 13. The method according to claim 1, further comprising forming a molding slot in the molding at a bending region of the article of footwear, wherein a thickness of the molding is reduced along the molding slot. 14. The method according to claim 1, wherein the full length composite plate comprises a first plurality of layers alternating with a second plurality of layers; wherein each layer of the first plurality of layers comprises a full length non-woven sheet;wherein each layer of the second plurality of layers comprises a full length woven fiber sheet;wherein each layer of the first plurality of layers has a first thickness;wherein each layer of the second plurality of layers has a second thickness;wherein the full length composite plate further comprises a first tie layer disposed on a first side of the alternating first and second pluralities of layers and a second tie layer disposed on a second side of the alternating first and second pluralities of layers opposite to the first side;wherein the first tie layer and the second tie layer each have a third thickness;wherein the third thickness is greater than the first thickness and the second thickness;wherein the full length composite plate, as measured as a single component comprising the first plurality of layers, the second plurality of layers, the first tie layer, and the second tie layer, has a percent elongation greater than 2 percent and a thickness less than or equal to approximately 2 mm;wherein the first tie layer provides the first side of the full length composite plate; andwherein the second tie layer provides the second side of the full length composite plate. 15. A method of making an article of footwear comprising: positioning a full length composite plate between a molding base and a mold, the composite plate including a first side in opposed contact with a support surface of the molding base, a second side disposed on an opposite side of the composite plate than the first side and opposing a mold surface of the mold, an arcuate lateral edge extending continuously along a lateral side of the footwear from a forefoot region to a heel region, and an arcuate medial edge extending continuously along a medial side of the footwear from the forefoot region to the heel region and cooperating with the lateral edge to bound an uninterrupted surface extending continuously from a heel end of the composite plate to a forefoot end of the composite plate and between the lateral edge and the medial edge;moving at least one of the mold and the molding base toward the other of the mold and the molding base to enclose the composite plate within a cavity of the mold;filling the cavity with a liquid or viscous substance to cover the second side of the composite plate; andsolidifying the liquid or viscous substance to form a molding attached to the second side of the composite plate. 16. The method according claim 15, wherein injecting the liquid or viscous substance into the cavity includes applying the liquid or viscous substance to at least one of the medial edge and the lateral edge of the full length composite plate. 17. The method according to claim 16, wherein injecting the liquid or viscous substance into the cavity includes applying the liquid or viscous substance around an entire perimeter of the full length composite plate. 18. The method according to claim 15, wherein the mold surface of the mold contacts the support surface of the molding base at a location spaced apart from a perimeter of the full length composite plate, wherein a portion of the support surface of the molding base is exposed to the cavity between the perimeter of the full length composite plate and a cavity rim defining an outer periphery of the cavity, wherein the portion of the support surface of the molding base that is exposed to the cavity is in contact with the liquid or viscous substance such that the liquid or viscous substance is disposed flush with the first side of the full length composite plate. 19. The method according to claim 15, wherein the full length composite plate comprises a first plurality of layers alternating with a second plurality of layers; wherein each layer of the first plurality of layers comprises a full length non-woven sheet;wherein each layer of the second plurality of layers comprises a full length woven fiber sheet;wherein each layer of the first plurality of layers has a first thickness;wherein each layer of the second plurality of layers has a second thickness;wherein the full length composite plate further comprises a first tie layer disposed on a first side of the alternating first and second pluralities of layers and a second tie layer disposed on a second side of the alternating first and second pluralities of layers opposite to the first side;wherein the first tie layer and the second tie layer each have a third thickness;wherein the third thickness is greater than the first thickness and the second thickness;wherein the full length composite plate, as measured as a single component comprising the first plurality of layers, the second plurality of layers, the first tie layer, and the second tie layer, has a percent elongation greater than 2 percent and a thickness less than or equal to approximately 2 mm;wherein the first tie layer provides the first side of the full length composite plate;wherein the second tie layer provides the second side of the full length composite plate; andwherein the molding is attached to the second tie layer of the full length composite plate. 20. A method of making an article of footwear comprising: positioning a full length composite plate between a molding base and a mold, the composite plate including a first side in opposed contact with a support surface of the molding base, a second side disposed on an opposite side of the composite plate than the first side and opposing a mold surface of the mold, and an uninterrupted surface extending continuously from a heel end of the composite plate to a forefoot end of the composite plate and between and bounded by a continuous curved outer perimeter edge of the composite plate proximate an outer perimeter of the footwear;moving at least one of the mold and the molding base toward the other of the mold and the molding base to enclose the composite plate within a cavity of the mold;filling the cavity with a liquid or viscous substance to cover the second side of the composite plate; andsolidifying the liquid or viscous substance to form a molding attached to the second side of the composite plate. 21. A method of making an article of footwear comprising: associating a full length composite plate with a first side of a molding base, a first surface of the full length composite plate confronting the first side of the molding base, the full length composite plate also including a second surface disposed opposite to the first surface;associating a first side of a mold with the first side of the molding base, enclosing the full length composite plate within a central cavity disposed within the mold;filling the central cavity with a liquid or viscous substance through at least one injection channel in the mold;wherein the liquid or viscous substance fills substantially an entirety of the central cavity and contacts the second surface of the full length composite plate;wherein the full length composite plate comprises a first plurality of layers alternating with a second plurality of layers;wherein each layer of the first plurality of layers comprises a full length non-woven sheet;wherein each layer of the second plurality of layers comprises a full length woven fiber sheet;wherein each layer of the first plurality of layers has a first thickness;wherein each layer of the second plurality of layers has a second thickness;wherein the full length composite plate further comprises a first tie layer disposed on a first side of the alternating first and second pluralities of layers and a second tie layer disposed on a second side of the alternating first and second pluralities of layers opposite to the first side;wherein the first tie layer and the second tie layer each have a third thickness;wherein the third thickness is greater than the first thickness and the second thickness;wherein the full length composite plate, as measured as a single component comprising the first plurality of layers, the second plurality of layers, the first tie layer, and the second tie layer, has a percent elongation greater than 2 percent and a thickness less than or equal to approximately 2 mm;wherein the first tie layer provides the first surface of the full length composite plate;wherein the second tie layer provides the second surface of the full length composite plate;wherein the method further comprises forming a molding from the liquid or viscous substance in the central cavity; andwherein the liquid or viscous substance solidifies to form a molding that is attached to the first tie layer of the full length composite plate. 22. A method of making an article of footwear comprising: placing a full length composite plate between a mold and a molding base, wherein the full length composite plate has a first side facing the mold and a second side opposite to the first side and facing the molding base;positioning the full length composite plate within a central cavity defined by the mold and the molding base;injecting molding material into the central cavity through at least one injection channel in the mold;filling the central cavity with the molding material and contacting the first side of the full length composite plate with the molding material;wherein the molding material solidifies to form a molding attached to the first side of the full length composite plate;wherein the full length composite plate comprises a first plurality of layers alternating with a second plurality of layers;wherein each layer of the first plurality of layers comprises a full length non-woven sheet;wherein each layer of the second plurality of layers comprises a full length woven fiber sheet;wherein each layer of the first plurality of layers has a first thickness; wherein each layer of the second plurality of layers has a second thickness;wherein the full length composite plate further comprises a first tie layer disposed on a first side of the alternating first and second pluralities of layers and a second tie layer disposed on a second side of the alternating first and second pluralities of layers opposite to the first side;wherein the first tie layer and the second tie layer each have a third thickness;wherein the third thickness is greater than the first thickness and the second thickness;wherein the full length composite plate, as measured as a single component comprising the first plurality of layers, the second plurality of layers, the first tie layer, and the second tie layer, has a percent elongation greater than 2 percent and a thickness less than or equal to approximately 2 mm;wherein the first tie layer provides the first side of the full length composite plate;wherein the second tie layer provides the second side of the full length composite plate; andwherein the molding is attached to the second tie layer of the full length composite plate.
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