JP7584669B2 - Footwear with protruding members and method of forming a cleat assembly - Patents.com - Google Patents

Description

The present disclosure generally relates to footwear including a cleat assembly having a protruding member extending from a base.

Many conventional shoes or footwear generally include an upper and a sole attached to the lower end of the upper. Conventional shoes further include an interior space, i.e., a void or cavity, formed by the upper and the inner surface of the sole to accommodate the wearer's foot prior to fastening the shoe to the foot. The sole is attached to the lower surface of the upper and is disposed between the upper and the ground. As a result, the sole typically provides stability and cushioning to the wearer when the shoe is being worn and/or used. In some examples, the sole may include multiple components, such as an outsole, a midsole, and an insole. The outsole may provide traction to the bottom surface of the sole, and the midsole may be attached to the inner surface of the outsole and may provide cushioning and/or additional stability to the sole. For example, the sole may include certain foam materials that may increase stability at one or more desired locations along the sole, or foam materials that may reduce stress or impact energy to the foot and/or leg during running, walking, or another activity.

The upper generally defines an interior cavity that extends upward from the sole and completely or partially encases the foot. In most cases, the upper extends over the instep and toe regions of the foot, as well as across the medial and lateral sides thereof. Many footwear items may also include a tongue that extends across the instep region and bridges the gap between the edges of the upper that define an opening into the cavity. The tongue may also be provided to allow adjustment of the tightness of the shoe, and may be provided under a lacing system that may be operable by the user to allow entry and/or exit of the foot from the interior space or cavity. In addition, the lacing system may allow the wearer to adjust certain dimensions of the upper and/or sole, thereby allowing the upper to accommodate a wide variety of foot types having different sizes and shapes.

Many shoe uppers can include a wide variety of materials that can be utilized to form the upper and can be selected for use based on one or more intended uses of the shoe. The upper may also include portions that include various materials specific to particular areas of the upper. For example, additional stability may be desired adjacent the front or heel area of the upper to provide a higher degree of resistance or stiffness. In contrast, other portions of the shoe may include soft woven fabrics to provide areas that are stretch-resistant, flexible, breathable, or moisture-wicking.

However, in many cases, footwear is desired that has an upper that provides improved comfort and a better fit, along with a sole that has improved structural characteristics, such as a cleat assembly secured to the sole structure for improved ground traction.

The footwear described herein can have a variety of configurations. The footwear may have an upper and a sole structure connected to the upper.

Some embodiments of the present disclosure provide footwear including an upper, a sole structure connected to the upper, and a cleat assembly connected to the sole structure. The cleat assembly can include a first protruding member extending from a first base. The first protruding member can define a first midfoot-facing portion and a forefoot-facing portion. The second protruding member can extend from a second base and can define a second midfoot-facing portion and a heel-facing portion. A first acute angle can be defined by the first base and the first midfoot-facing portion. A first obtuse angle can be defined by the first base and the forefoot-facing portion. A second acute angle can be defined by the second base and the second midfoot-facing portion. A second obtuse angle can be defined by the second base and the heel-facing portion.

In some embodiments, the footwear can include a first obtuse angle and a second obtuse angle between 95 degrees and 145 degrees, inclusive.

In some embodiments, the footwear can include a first acute angle and a second acute angle, both between 35 and 85 degrees.

In some embodiments, the footwear can include a first base formed from a forefoot portion of the cleat assembly. The forefoot portion of the cleat assembly can be at least partially disposed in a forefoot region of the footwear. The second base can be formed from a heel portion of the cleat assembly. The heel portion of the cleat assembly can be at least partially disposed in a heel region of the footwear.

In some embodiments, the footwear can include a first protruding member that is part of a first plurality of protruding members. The second protruding member can be part of a second plurality of protruding members.

In some embodiments, the footwear may include at least one protruding member of the first or second plurality of protruding members that includes a ground-engaging surface that is parallel to a portion of the base.

In some embodiments, the footwear may include a first plurality of protruding members and a second plurality of protruding members. Each of the protruding members of the first and second plurality of protruding members may be angled toward a midfoot region of the footwear.

In some embodiments, the footwear can include a first plurality of integrally formed protruding members. A second plurality of integrally formed protruding members can additionally or alternatively be formed.

In some embodiments, the footwear may include one or more protruding members that include removable stud tips.

In some embodiments, the footwear may include one or more protruding members that are injection molded from a scratch resistant polymer, such as, for example, polybenzimidazole, polyparaphenylene, polyetheretherketone, polyimide, acrylonitrile butadiene styrene, coated polypropylene, or other additives added to a polymer such as polypropylene.

In some embodiments, the footwear can include a first protruding member that includes a tapered shape such that a wider portion of the first protruding member is disposed proximate the first base, and the second protruding member can include a tapered shape such that a wider portion of the second protruding member is disposed proximate the second base.

Some embodiments of the present disclosure provide footwear including an upper, a sole structure connected to the upper and defining a forefoot region, a midfoot region, and a heel region, and a cleat assembly secured to the sole structure. The cleat assembly can include a forefoot portion secured to the sole structure at the forefoot region. The forefoot portion can include a first plurality of protruding members extending from a first base. The first plurality of protruding members can be angled toward the midfoot region. A heel portion of the cleat assembly can be secured to the sole structure at the heel region. The heel portion can include a second plurality of protruding members extending from a second base. The second plurality of protruding members can be angled toward the midfoot region.

In some embodiments, the footwear may include a plurality of protruding members. Each protruding member of the plurality of protruding members may include a ground-engaging surface. Each ground-engaging surface may define a surface area that may vary between the protruding members. A surface of a protruding member closest to a midfoot region of the footwear may be greater than a surface area of a protruding member closest to a forefoot or heel region of the footwear.

In some embodiments, the footwear may include a plurality of protruding members including removable stud tips.

In some embodiments, the footwear may include a first base integrally formed with the first protruding member and a second base integrally formed with the second protruding member. Each of the bases may be separate and distinct.

In some embodiments, the footwear can include a protruding member in a forefoot region that can define a midfoot-facing sidewall and a forefoot-facing sidewall (e.g., when viewed from the side of the footwear). The midfoot-facing sidewall can form an acute angle with the base, and the forefoot-facing sidewall can form an obtuse angle with the base. Generally, the protruding member can extend downwardly from the base.

In some embodiments, the footwear may include a protruding member having a midfoot-facing sidewall and a forefoot-facing sidewall integrally formed with one another.

In some embodiments, the footwear can include a protruding member in a heel region that can define a midfoot-facing sidewall and a heel-facing sidewall (e.g., when viewed from the side of the footwear). The midfoot-facing sidewall can form an acute angle with the base, and the heel-facing sidewall can form an obtuse angle with the base. Generally, the protruding member can extend downwardly from the base.

Some embodiments of the present disclosure provide a method of forming a cleat assembly for footwear. The method can include injecting a first material into a mold cavity to form a cleat assembly. The mold cavity can include a plurality of stud recesses each defining a respective stud recess base disposed along an incline that defines an acute exterior angle with respect to a horizontal plane. The horizontal plane can be disposed outside the mold cavity. The method can also include removing the cleat assembly from the mold cavity at an angle substantially perpendicular to the horizontal plane.

In some embodiments, a method of forming a cleat assembly for footwear can include securing the cleat assembly to a sole structure of the footwear.

Some embodiments of the present disclosure provide footwear including an upper, a sole structure, and a cleat assembly connected to the sole structure. The cleat assembly includes a plurality of protruding members extending from a base. Each protruding member includes a sidewall that defines a first exterior angle and a second exterior angle relative to the base when viewed from one of the medial or lateral sides of the footwear. The first exterior angle is greater than the second exterior angle.

In some embodiments, the present disclosure provides footwear including an upper, a sole structure connected to the upper, and a cleat assembly connected to the sole structure. The cleat assembly can include a first protruding member extending from a first base. The first protruding member can define a first midfoot-facing portion and a forefoot-facing portion. The second protruding member can extend from a second base and can define a second midfoot-facing portion and a heel-facing portion. A first acute angle can be defined by the first base and the first midfoot-facing portion. A first obtuse angle can be defined by the first base and the forefoot-facing portion. A second acute angle can be defined by the second base and the second midfoot-facing portion. A second obtuse angle can be defined by the second base and the heel-facing portion.

Other aspects of the footwear, including its features and advantages, will be apparent to one of ordinary skill in the art upon review of the drawings and detailed description herein. Accordingly, all such aspects of the footwear are intended to be included in the detailed description and this summary.

FIG. 1 is a top side isometric view of an article of footwear configured as a left shoe including a cleat assembly according to an embodiment of the disclosure. FIG. 2 is a side view of the footwear of FIG. 1 . FIG. 2 is a top view of the footwear of FIG. 1 . 2 is a schematic diagram of an upper layer of the footwear of FIG. 1; 2 is a schematic view of a portion of the tongue of the footwear of FIG. 1; FIG. 2 is a schematic diagram of a mold for a portion of the cleat assembly of FIG. 1. FIG. 7 is a schematic diagram of a mold opening of the mold of FIG. 6. FIG. 2 is a side view of a protruding member of the cleat assembly of FIG. 1 . 1 is a schematic diagram of a profile of a protrusion member according to an embodiment of the present disclosure. 13 is another schematic diagram of a profile of a protruding member according to an embodiment of the present disclosure. FIG. 2 is a medial side view of a sole structure for footwear including a cleat assembly according to an embodiment of the present disclosure. FIG. 12 is a bottom view of the sole structure of FIG. FIG. 12 is a side view of the sole structure of FIG. FIG. 13 is a cross-sectional side view of the sole structure of FIG. 12 taken along line AA. FIG. 12 is a top view of the sole structure of FIG. 13 is a cross-sectional view of the sole structure of FIG. 12 taken along line BB. 13 is a cross-sectional view of the sole structure of FIG. 12 taken along line CC. 13 is a cross-sectional view of the sole structure of FIG. 12 taken along line DD. 13 is a cross-sectional view of the sole structure of FIG. 12 taken along line EE. 13 is a cross-sectional view of the sole structure of FIG. 12 taken along line FF. 13 is a cross-sectional view of the sole structure of FIG. 12 taken along line G-G. FIG. 2 is a schematic diagram of a mold for a cleat assembly according to an embodiment of the present disclosure.

The following description and accompanying drawings disclose various embodiments or configurations of shoes that may include uppers and sole structures. Although embodiments of the shoes or sole structures are disclosed with respect to athletic shoes, such as running shoes, tennis shoes, and basketball shoes, the concepts related to the embodiments of the shoes or sole structures may be applied to a wide range of footwear and footwear styles, including, for example, cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and cleats, walking shoes, and track and field cleats. The concepts of the shoes or sole structures may also be applied to articles of footwear that are considered non-athlete, including dress shoes, sandals, loafers, slippers, and heels. In addition to footwear, certain concepts described herein may also be applied to and incorporated into other types of apparel or other athletic equipment, including helmets, padding or protective padding, shin guards, and gloves. Additionally, certain concepts described herein may be incorporated into cushions, backpack straps, golf clubs, or other consumer or industrial products. Thus, the concepts described herein may be utilized in a variety of products.

When the term "about" is used herein, it refers to, for example, typical measuring and manufacturing procedures used for footwear or other products that may include embodiments of the disclosures herein, variations in numerical quantities that may occur through inadvertent errors in these procedures, differences in manufacture, source, or purity of ingredients used to make a composition or mixture, and the like. Throughout this disclosure, the terms "about" and "approximately" refer to a range of values of ±5% of the numerical value that the term precedes.

The terms "weight percent," "wt-%," "percent by weight," "wt. %," 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, for example, the total weight of the composition or a particular component of a composition, multiplied by 100. As used herein, it is understood that "percent," "%," and the like, can be synonymous with "weight percent" and "wt-%."

The present disclosure is directed to footwear and/or specific components of footwear, such as uppers and/or soles or sole structures. The uppers may include knitted components, wovens, and/or nonwovens.
The knitted component may be produced by knitting yarns, the woven fabric may be produced by weaving yarns, and the nonwoven fabric may be produced by manufacturing a single layer nonwoven fabric. The knitted fabric includes fabrics formed by warp knitting, weft knitting, reciprocating knitting, circular knitting, and/or other suitable knitting operations. The knitted fabric may have, for example, a plain knit construction, a mesh knit construction, and/or a rib knit construction. The woven fabric may include, for example, but is not limited to, fabrics formed by any of a number of weaving configurations, such as plain weave, twill weave, satin weave, dobby weave, jacquard weave, double weave, and/or double cloth weave. The nonwoven fabric may include, for example, fabrics produced by airlaid and/or spunlaid processes. The upper may comprise various materials, such as first yarns, second yarns, and/or third yarns, which may have different properties or different visual properties.

1-3 show an exemplary embodiment of footwear 100 including an upper 102 and a sole structure 104. The upper 102 is attached to the sole structure 104, which together define an interior cavity 106 into which the foot may be inserted. For reference, the footwear 100 defines a forefoot region 108, a midfoot region 110, and a heel region 112. The forefoot region 108 generally corresponds to the portion of the footwear 100 that encases portions of the foot, including the toes, the ball of the foot, and the joints that connect the metatarsals to the toes or phalanges. The midfoot region 110 is closely adjacent to the forefoot region 108 and generally corresponds to the portion of the footwear 100 that encases the arch of the foot, along with the bridge of the foot. The heel region 112 is closely adjacent to the midfoot region 110 and generally corresponds to the portion of the footwear 100 that wraps around the rear of the foot, including the heel or calcaneus, ankle, and/or Achilles tendon.

Many conventional footwear uppers are formed from multiple elements (e.g., textiles, polymer foams, polymer sheets, leather, and synthetic leather) that are joined by bonding or stitching. In particular, with reference to FIGS. 4 and 5, the upper 102 may be formed from a first layer 114 and a second layer 116. The first layer 114 may include a plurality of recesses 118 configured as holes that facilitate breathability through the upper 102. The second layer 116 may be at least partially transparent and pressed onto the first layer 114. As shown in FIG. 4, the second layer 116 may be configured as a skin having a pattern, such as dots or pixels. As shown in FIG. 5, the tongue 120 of the footwear 100 similarly includes a first layer 114 having a plurality of recesses 118 to further enhance the breathability of the upper 102.

Footwear 100 also includes a medial side 122 and a lateral side 124, shown in FIG. 3. In particular, the lateral side 124 corresponds to the lateral portion of footwear 100, and the medial side 122 corresponds to the medial portion of footwear 100. Thus, the left and right footwear have opposing lateral and medial sides, such that the medial side 122 is closest to each other when the footwear 100 is worn by a user, while the lateral side 124 is defined as the side furthest from each other during wear. The medial side 122 and the lateral side 124 are adjacent to each other at opposite distal ends of footwear 100.

Unless otherwise specified, the forefoot region 108, midfoot region 110, heel region 112, medial side 122, and lateral side 124 are intended to define boundaries or regions of the footwear 100. To that end, the forefoot region 108, midfoot region 110, heel region 112, medial side 122, and lateral side 124 generally characterize sections of the footwear 100. Additionally, both the upper 102 and sole structure 104 may be characterized as having a forefoot region 108, midfoot region 110, heel region 112, and portions within the medial side 122 and lateral side 124. Thus, the upper 102 and sole structure 104, and/or individual portions of the upper 102 and sole structure 104 may include portions thereof that are disposed within the forefoot region 108, midfoot region 110, heel region 112, and medial side 122 and lateral side 124.

The sole structure 104 is connected or secured to the upper 102 and extends between the user's foot and the ground when the footwear 100 is worn by a user. The sole structure 104 may 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, the sole structure may include an outsole that provides structural integrity to the sole structure and traction to the user, a midsole that provides a cushioning system, and an insole that supports the user's arch.

1 and 2, the sole structure 104 includes a cleat assembly 130. The cleat assembly 130 includes a forefoot portion 132 and a heel portion 134. The forefoot portion 132 includes a plurality of protruding members 136 and a base portion 138. The plurality of protruding members 136 extend from the base portion 138 and can define at least two distinct angles between a sidewall 140 of each protruding member 136 and the base portion 138 in a side view.

In the illustrated embodiment, the sidewall 140 is configured as an outer surface of a cylinder. For example, as shown in FIGS. 1 and 2, the cylinder may be configured as a tapered cylinder (e.g., a frustum) having a wider portion disposed proximate the base 138. In other embodiments, the protruding member 136 may be faceted, and the sidewall may be only a single facet of the faceted outer surface of the protruding member 136. Thus, a first sidewall defined by a first facet may define a first angle between the first facet and the base 138, and a second sidewall defined by a second facet of the same protruding member may define a second angle between the second facet and the base 138. The first angle may be different from the second angle.

The distinct and distinct angles of the protruding members 136 formed by the sidewalls 140 and the base 138 when viewed in side view may vary between individual protruding members 136 of the plurality of protruding members. Further details of such distinct angles are described below with reference to Figures 8-10. Similarly, the heel portion 134 includes a plurality of protruding members 144 extending from a base 146. As with the forefoot portion 132, one or more of the protruding members 144 of the heel portion 134 may define at least two distinct angles between the sidewalls 148 and the base 146 of each protruding member 144.

Each of the plurality of protruding members 136, 144 includes a respective ground-engaging surface 150 that is generally bounded by a respective sidewall 140, 148. In embodiments in which the plurality of protruding members 136, 144 include faceted surfaces, the ground-engaging surface may generally be bounded by the faceted surfaces. Each protruding member 136 of the forefoot portion 132 may include a ground-engaging surface 150 of various sizes (e.g., surface area). For example, the ground-engaging surface 150 of a protruding member 136 closer to the midfoot region 110 of the footwear 100 may be larger than the ground-engaging surface 150 of a protruding member 136 closer to the forefoot region 108. Similarly, the surface area of the ground-engaging surface 150 may vary with respect to the position of the protruding member 136 relative to the medial side 122 and lateral side 124 of the footwear 100. In the illustrated embodiment, the ground-engaging surface 150 is generally planar. However, in other embodiments, the protruding members may include a ground-engaging surface having a generally convex or concave geometry.

Generally, each of the forefoot portion 132 and heel portion 134 of the cleat assembly 130 may be formed by injection molding. For example, in some embodiments, an injection mold such as the mold 160 shown in FIG. 6 may be used to form the forefoot portion 132 of the cleat assembly 130. The mold 160 is configured as a two-piece rigid mold and includes a cavity 162 having a plurality of recesses corresponding to the geometric shape of the plurality of protruding members 136. The cavity 162 is formed in a beveled portion 164 of the mold 160. The beveled portion 164 relative to the cavity 162 facilitates successful removal of the forefoot portion 132 of the cleat assembly 130 from the mold 160 and eliminates an undercut shape of the cleat assembly 130.

In some embodiments, during the manufacturing process, preformed stud tips may be added to the cavity 162 and inserted into the recesses prior to the injection molding process. The preformed stud tips may be formed from a material different than the injected material to form the cleat assembly 130. For example, the stud tips may be formed from a material that is relatively more abrasion or scratch resistant as compared to the injected material, which may be a polymeric injected material. Additionally, in some embodiments, the cleat assembly 130 may include removable stud tips. For example, the stud tips may be secured to the forefoot portion 132 and heel portion 134 via threaded fasteners.

7, the portion of the mold 160 corresponding to the ground-engaging surface 150 of the protruding member 136 is generally parallel (e.g., acute or substantially parallel) to the angled portion 164 of the mold 160. Such a geometry further reduces undercut features formed in the cleat assembly 130. The corresponding molds and mold features shown in FIGS. 6 and 7 can be used to manufacture the heel portion 134 of the cleat assembly 130.

8 shows a single protruding member 136A of the forefoot 132 of the cleat assembly 130. It should be understood that the protruding member 136A is shown by way of example and can correspond to any one or more of the protruding members 136, 144. In particular, the reference lines shown in FIG. 8 can generally correspond to any one of the protruding members 136, 144, regardless of their relative angle relative to an axis, such as axis 170 extending along the base 138 adjacent one of the multiple protruding members 136 in an elevated side view. In this regard, the reference lines (e.g., lines 172, 174) can correspond to various side walls of the protruding members 134, 144 and can intersect the reference line (e.g., line 170) at various angles.

In the illustrated embodiment, the protruding member 136A defines an axis 170 extending along the base 138. A first portion of the sidewall 140 is disposed at least partially along a first line 172, and a second portion of the sidewall 140 is disposed along a second line 174. The first line 172 intersects the axis 170 at a first exterior angle 176, and the second line 174 intersects the axis 170 at a second exterior angle 178. The first exterior angle 176 is obtuse (i.e., greater than 90 degrees) and faces the forefoot region 108 of the footwear 100 (see, e.g., FIGS. 1 and 2). The second exterior angle 178 is acute (i.e., less than 90 degrees) and faces the midfoot region 110 of the footwear 100. In general, the angles shown in FIG. 8 can facilitate removal from an injection mold while providing sufficient ground contact area and strength during use.

Each protruding member 144 of the heel portion 134 can define a corresponding first exterior angle formed by the base 146 and the portion of the sidewall 148 that faces the heel region 112 of the footwear 100. In addition, each protruding member 144 of the heel portion 134 can define a corresponding second exterior angle formed by the base 146 and the portion of the sidewall 148 that faces the midfoot region 110 of the footwear 100. Similar to the protruding member 136A, the first exterior angle of the protruding member 144 of the heel portion 134 is an obtuse angle, and the second exterior angle of the protruding member 144 of the heel portion 134 is an acute angle.

Generally, the first exterior angle 176 may be between about 95 degrees and 145 degrees. Additionally, the second exterior angle 178 may be between about 35 degrees and 85 degrees. Thus, each exterior angle of the protruding members 136, 144 facing the outer end of the footwear 100 (i.e., the forefoot region 108 or the heel region 112) may be between about 95 degrees and 145 degrees. Additionally or alternatively, each exterior angle of the protruding members 136, 144 facing the midfoot region 110 of the footwear 100 may be between about 45 degrees and 85 degrees.

9 and 10 illustrate additional geometric shapes of protruding members according to some embodiments of the present disclosure. For example, FIG. 9 shows a protruding member 200 extending from a base surface 202 and including a sidewall 204 and a ground-engaging surface 206. One side of the sidewall 204 facing an end of the footwear (i.e., the forefoot region or heel region) forms a first angle 208 with the base surface 202. A second side of the sidewall 204 facing a midfoot region of the footwear forms a second angle 210 with the base surface 202. In the illustrated example, the first angle 208 is approximately 110 degrees and the second angle 210 is approximately 70 degrees.

10 shows a protruding member 220 extending from a base surface 222 and including a sidewall 224 and a ground-engaging surface 226. One sidewall 224 facing an end of the footwear forms a first angle 228 with the base surface. A second side of the sidewall 224 facing a midfoot region of the footwear forms a second angle 230 with the base surface 222. In the illustrated example, the first angle 228 is approximately 110 degrees and the second angle 230 is approximately 80 degrees.

The ground-engaging surfaces 206, 226 shown in Figures 9 and 10, respectively, are generally parallel to the corresponding base surfaces 202, 222. However, in other embodiments, one or more ground-engaging surfaces of the cleat assembly may be angled relative to the base. Each of the protruding members 200, 220 provides an exemplary geometry that may be used by one or more of the multiple protruding members 136, 144 of the cleat assembly 130.

11-21 show an exemplary embodiment of a sole structure 240 according to an embodiment of the present invention. Similar to sole structure 104, sole structure 240 is attached to an upper and configured to together define an interior cavity into which a foot can be inserted. For reference, sole structure 240 defines a forefoot region 248, a midfoot region 250, and a heel region 252. Forefoot region 248 generally corresponds to the portion of footwear, such as footwear 100, that encases the portions of the foot including the toes, the ball of the foot, and the joints that connect the metatarsals to the toes or phalanges. Midfoot region 250 is adjacent to and contiguous with forefoot region 248 and generally corresponds to the portion of footwear that encases the arch of the foot along with the bridge of the foot. The heel region 252 is closely adjacent to the midfoot region 250 and generally corresponds to the portion of the footwear that wraps around the rear of the foot, including the heel or calcaneus, ankle, and/or Achilles tendon.

The sole structure 240 also includes an inner surface 256, shown in FIG. 11, and an outer surface 258, shown in FIG. 13. In particular, the outer surface 258 corresponds to an outer portion of the footwear, and the inner surface 256 corresponds to an inner portion of the footwear. Thus, the left and right footwear have opposing outer and inner surfaces, such that the inner surfaces are closest to each other when the footwear is worn by a user, while the outer surfaces are defined as the sides furthest from each other while worn. The inner surface 256 and the outer surface 258 are adjacent to each other at opposite distal ends of the footwear.

Similar to the sole structure 104, the sole structure 240 includes a cleat assembly 260. The cleat assembly 260 includes a forefoot portion 262 and a heel portion 264. The forefoot portion 262 includes a plurality of protruding members 266 and a base 268. The plurality of protruding members 266 can extend from the base 268 and define a first exterior angle 270 and a second exterior angle 272 relative to the base 268. Similarly, the heel portion 264 includes a plurality of protruding members 274 extending from the base 276. Similar to the forefoot portion 262, one or more of the protruding members 274 of the heel portion 264 can define a first exterior angle 278 and a second exterior angle 280.

In some embodiments, the forefoot portion 262 can include a unitary body such that the plurality of protruding members 266 and the base portion 268 are integrally formed. Similarly, the heel portion 264 can include a unitary body such that at least one of the plurality of protruding members 274 is integrally formed with the base portion 274. In other embodiments, the forefoot portion 262 and the heel portion 264 can each include one or more base portions 268, 274, respectively.

11 and 13, each of the first exterior angles 270, 278 faces the outer edge of the sole structure 240 (i.e., the forefoot region 248 or the heel region 252) and each of the second exterior angles 272, 280 faces the center of the sole structure 240 (i.e., the midfoot region 250). The first exterior angles 270, 278 are approximately 95 degrees to 145 degrees. The second exterior angle 280 is approximately 35 degrees to 85 degrees.

16-21, a plurality of protruding members 266, 274 extend generally vertically downward from respective bases 268, 276 when viewed from the toe or heel end of the footwear. Additionally, each protruding member 266, 274 may include a stud member 282 extending beyond the respective protruding member 266, 274 forming a ground-engaging surface 284. As shown in FIGS. 16 and 21, some of the ground-engaging members 284 of the cleat assembly 260 may be disposed on substantially the same plane. Additionally, as shown in FIG. 17, some of the ground-engaging surfaces 284 of the cleat assembly 260 may be disposed on separate planes.

22 illustrates a mold 300 for a sole structure, such as sole structure 104. Similar to sole structure 104, mold 300 can include a forefoot portion 302 and a heel portion 304. Generally, mold 300 defines a negative space that includes a plurality of stud recesses 308 (e.g., stud recesses 308A-D). Each of the plurality of stud recesses 308 defines a respective base 310 (e.g., bases 310A-D). Each of the plurality of bases 310 in forefoot portion 302 is generally disposed along a slope 312. For example, a first stud recess 308A of the plurality of stud recesses 308 defines a first base 308A disposed along a first slope, a second stud recess 308B defines a second base 310B disposed along a second slope, and a third stud recess 308C defines a third base 308C disposed along a third slope.

In the illustrated embodiment, each of the first, second, and third slopes is inclined in the same direction as the general slope 312. Furthermore, in the illustrated embodiment, the first sloped portion of the first base 310A is slightly skewed (e.g., less than 30 degrees) relative to the general slope 312, and the third sloped portion of the third base 310C is slightly skewed (e.g., less than 10 degrees) relative to the general slope 312. Furthermore, as illustrated, the general slope 312, and therefore each of the first, second, and third slopes, form an acute angle with respect to the horizontal plane 318. The fourth stud recess 308D formed in the heel portion 304 defines a fourth base 308D disposed along a slope having a slope opposite to the general slope 312 of the forefoot portion 302.

The slope of each base 310 of the plurality of stud recesses 308 allows the sole structure to be removed from the mold 300 approximately perpendicular to the horizontal plane 318. When material is injected into the mold 300 to form the sole structure, the general slope (e.g., slope 312) of each of the forefoot and heel portions 302 and 304 allows the studs formed in the corresponding plurality of stud recesses 308 to define a straight centerline 320 that is generally perpendicular to the horizontal plane 318. In addition, the general slope of each of the forefoot and heel portions 302 and 304 prevents undercuts in the mold that can lock the sole structure in the mold 300.

Generally, the above-described protruding members, such as protruding members 136, 144, 200, 220, 266, 274, provide structure for the cleat assemblies, each of which is generally angled toward the midfoot of the footwear. Similarly, the above-described mold 300 provides a mold for a sole structure having cleat members generally angled toward the midfoot of the footwear. Such cleat members can provide an aggressive style that can enhance traction. Furthermore, the geometry of such cleat members facilitates an injection molding process that overcomes the complexities of undercuts without introducing unnecessary parting lines.

Any of the embodiments described herein may be modified to include any of the structures or methods disclosed in connection with the different embodiments. Additionally, the disclosure is not limited to the type of footwear specifically shown. Additionally, the footwear aspects of any of the embodiments disclosed herein may be modified to work with any type of footwear, apparel, or other athletic equipment.

As previously mentioned, although the present invention has been described above with reference to specific embodiments and examples, it will be understood by those skilled in the art that the present invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications, and departures from the embodiments are intended to be encompassed by the claims appended hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference herein as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the present invention are set forth in the following claims.
[Industrial Applicability]

Numerous modifications to the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling one skilled in the art to make and use the invention. The exclusive rights to all modifications that come within the scope of the appended claims are reserved.

CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 63/137,899, filed January 15, 2021, the contents of which are incorporated by reference in their entirety and are considered part of this application.

Claims (15)

The forefoot area;
The heel area,
Upper and
a sole structure connected to the upper;
a cleat assembly connected to the sole structure, the cleat assembly comprising a plurality of protruding members;
The cleat assembly includes:
a first projecting member extending from the first base and defining a first midfoot-facing portion and a forefoot-facing portion;
a first stud member extending beyond the first projection member and defining a first ground engaging surface;
a second projecting member disposed in the heel region as a heel-most projecting member extending from a second base and defining a second midfoot-facing portion and a heel-facing portion;
a second stud member extending beyond the second projection member and defining a second ground engaging surface;
a first acute angle defined by the first base portion and the first metatarsal-facing portion;
a first obtuse angle defined by the first base and the forefoot-facing portion;
a second acute angle defined by the second base portion and the second metatarsal- facing portion; and
a second obtuse angle defined by the second base and the heel-facing portion; and
a third protruding member disposed in the forefoot region and being the closest protruding member to the second protruding member in the heel region among the plurality of protruding members in the forefoot region;
a third stud member extending beyond the third projection member and defining a third ground engaging surface;
The third ground engaging surface is coplanar with the second ground engaging surface and non-coplanar with the first ground engaging surface. each of the first obtuse angle and the second obtuse angle is greater than or equal to 95 degrees and less than or equal to 145 degrees;
2. The footwear of claim 1, wherein the first acute angle and the second acute angle are each greater than or equal to 35 degrees and less than or equal to 85 degrees. Footwear according to claim 1, wherein the first base is formed from a forefoot portion of the cleat assembly that is at least partially disposed in the forefoot region of the footwear, and the second base is formed from a heel portion of the cleat assembly that is at least partially disposed in the heel region of the footwear. Footwear according to claim 1, wherein the first protruding member is part of a plurality of protruding members formed integrally with one another, and the second protruding member is part of a second plurality of protruding members formed integrally with one another. Footwear according to claim 1, wherein the second protruding member is one of two protruding members in the heel region and the third protruding member is one of two protruding members in the rearmost portion of the forefoot region, and both protruding members in the heel region and both protruding members in the rearmost portion of the forefoot region all include ground-engaging surfaces that are in the same plane. Footwear according to claim 1, wherein the first protruding member is integrally formed with the first base, and the second protruding member is integrally formed with the second base. Footwear according to claim 1, wherein each of the first and second stud members is configured as a removable stud tip. Footwear according to claim 1, wherein the first stud member is a separate component from the first protruding member, and the second stud member is a separate component from the second protruding member. Footwear according to claim 1, wherein each of the first protruding member and the second protruding member comprises an injection-molded polymeric material that is scratch-resistant. Footwear according to claim 1, wherein the first protruding member includes a tapered shape having a circular cross-section such that a wider portion of the first protruding member is disposed adjacent to the first base, and the second protruding member includes a tapered shape such that a wider portion of the second protruding member is disposed adjacent to the second base. Upper and
a sole structure connected to the upper and defining a forefoot region, a midfoot region, and a heel region;
a cleat assembly secured to the sole structure;
The cleat assembly includes:
a forefoot section secured to the sole structure in the forefoot region and including a first plurality of protruding members extending from a first base, the first plurality of protruding members being integrally formed with the first base and angled toward the midfoot region, the first plurality of protruding members in the forefoot region including a rearmost portion of the protruding members in a medial region of the sole structure extending from the first base and defining a ground engaging surface;
a heel portion secured to the sole structure in the heel region and including a second plurality of projecting members extending from a second base, integrally formed with the second base, and angled toward the midfoot region, the second plurality of projecting members extending from the second base, including a heel-most projecting member in a medial region of the sole structure that defines a ground-engaging surface, and forming an acute angle between the second base and a midfoot-facing side of the heel-most projecting member and an obtuse angle between the second base and a heel-facing side of the heel-most projecting member;
Including,
In a medial region of the sole structure, the rearmost protruding member in the forefoot region is the protruding member closest to the heelmost protruding member in the heel region;
a ground engaging surface of the rearmost protruding member in the forefoot region is coplanar with a ground engaging surface of the heel-most protruding member in the heel region and is non-coplanar with a ground engaging surface of at least one protruding member of the first plurality of protruding members in the forefoot region. Footwear according to claim 11, further comprising a removable stud tip extending from each of the first and second plurality of protruding members. at least a portion of the first base is integrally formed with at least one protruding member of the first plurality of protruding members by injection molding;
The article of footwear recited in claim 11 , wherein at least a portion of the second base is integrally formed with at least one protruding member of the second plurality of protruding members by injection molding. 1. A method of forming a cleat assembly using a mold including a forefoot section and a heel section, comprising:
A method comprising: injecting a first material into a mold cavity in the forefoot portion of the mold to form a cleat assembly, the mold cavity including a plurality of stud recesses each defining a respective stud recess base disposed along a slope that defines an acute exterior angle with respect to a horizontal plane, each stud recess base being inclined along the slope; and removing the cleat assembly from the mold cavity at an angle substantially perpendicular to the horizontal plane. The method of claim 14, comprising inserting a plurality of stud tips into respective ones of the stud recesses prior to injecting the first material into the mold cavity.

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