CN118235912A - Article of footwear with sole plate - Google Patents

Abstract

A sole assembly for an article of footwear. The sole assembly includes a top mid-layer, a bottom mid-layer, and a plate disposed between the top mid-layer and the bottom mid-layer. The plate includes a forefoot portion having a lateral longitudinal extension, a medial longitudinal extension, and a central longitudinal extension, and a heel portion having a heel cup and a heel flange extending outwardly from the heel cup. The central longitudinal extension and the lateral longitudinal extension are connected by a bridge. The top mid-layer is seated in the heel cup and does not cover the upper surface of the heel flange. The bottom mid-layer is located below the heel flange and supports the heel flange.

Description

Footwear having a sole plate

Technical Field

The present invention relates to footwear, and more particularly to footwear including a sole assembly having a plate.

Background technique

A typical article of footwear includes an upper attached to a sole or sole assembly. The sole is located under the foot of the wearer and provides a ground contact surface that protects the wearer's foot. In addition to protecting the wearer's foot, the sole is generally designed to provide desired support, cushioning, and energy feedback. To achieve these goals, footwear with a variety of different soles or sole assemblies is available. In many articles of footwear, the sole assembly includes a plate that is significantly more rigid than the cushioning material included in the sole assembly. The plate is designed to bend under load during the initial portion of the wearer's stride to store energy, and then return to its original shape as the load decreases during the later portion of the wearer's stride (e.g., during toe-off).

The characteristics of the sole assembly are complex and depend to a great extent on a variety of factors, most notably the design and construction of the plate and the cushioning material combined with the plate. Therefore, a wide range of sole assemblies with plates have been developed for various applications such as hiking, walking, running and leisure activities. For example, the rigidity of the plate, the position of the plate in the sole assembly, the shape of the plate, the material of the plate, the cushioning performance of the cushioning material (e.g., midsole), the position of the cushioning material relative to the plate and the wearer's foot are all factors that promote the overall performance of the sole assembly. When desired, more rigid plates can be used to provide enhanced support, but they will increase weight and make the sole assembly less comfortable and too hard for a range of applications. By changing the size, shape and construction of the plate, the support and energy feedback characteristics provided by the plate can be localized or otherwise controlled to promote the overall characteristics of the sole assembly. Similarly, the cushioning material can be designed to accommodate the plate and give the sole assembly the desired cushioning, comfort and energy feedback characteristics. Too little cushioning material may not provide enough cushioning and may reduce the comfort of the sole assembly. On the other hand, too much cushioning material may make the sole assembly too thick and may reduce the effectiveness of the board by absorbing too much energy returned by the board.

As can be seen, a variety of properties can be intentionally adjusted to coordinate a plated sole assembly for an intended application. Despite this general recognition within the footwear industry, an ideal plated sole assembly has not yet been developed for many different footwear applications. Therefore, there remains a need for a plated sole assembly that provides an optimized combination of support, cushioning, and energy return for footwear articles that are intended for use in the field of running and other athletic activities.

Summary of the invention

An article of footwear includes a sole assembly having a plate disposed between a top midsole layer and a bottom midsole layer. The plate includes a heel portion, an arch portion, and a forefoot portion. The forefoot portion includes a medial extension extending longitudinally generally along a medial edge of a forefoot region, a central extension extending longitudinally through a substantial center of the forefoot region, and a lateral extension extending longitudinally along a lateral edge of the forefoot region. The central longitudinal extension and the lateral longitudinal extension are joined to each other at their front ends.

In one embodiment, the heel portion of the board includes an upwardly curved peripheral region to provide a slightly concave seat for the heel of the wearer's foot. In one embodiment, the arch portion also includes a peripheral region extending upwardly in unison with the peripheral region of the heel portion, whereby the arch region and the heel region cooperatively define a heel cradle that begins in the arch portion and extends to the rearmost end of the board. The heel cradle receives the heel portion of the top mid-bottom layer and receives the heel of the wearer's foot when worn. The complex curvature of the board in the heel region also enhances the stiffness of the board in the heel region, where the force of the heel striking the ground is primarily concentrated.

In one embodiment, an opening is defined through the approximate center of the heel region of the board. The opening may be generally oval in shape extending in the longitudinal direction. The heel opening allows communication between the upper midsole layer and the bottom midsole layer at the approximate center of the heel region, thereby providing enhanced centering and cushioning of the wearer's foot while also reducing the weight of the board.

In one embodiment, the medial extension is curved and extends along the medial peripheral edge of the sole, starting at the front end of the arch area and extending forward at least to a point under the big toe. The medial extension may be offset inwardly from the medial edge of the sole assembly and extend parallel to the medial edge.

In one embodiment, the lateral extension is curved and extends along the lateral peripheral edge of the sole, starting at the front end of the arch area and extending forward at least to a point below the little toe. The lateral extension may be offset inwardly from the lateral edge of the sole assembly and extend parallel to the lateral edge.

In one embodiment, the central longitudinal extension is generally straight, commencing at the front end of the arch region and extending forwardly to a point between the end of the medial longitudinal extension and the lateral longitudinal extension.

In another embodiment, the plate includes a lateral bridge extending slightly laterally between the front ends of the central extension and the lateral extension. The bridge may have approximately the same width as the central extension and the lateral extension. In one embodiment, the central extension, the lateral extension, and the lateral bridge cooperatively define a closed opening in the forefoot region.

In yet another embodiment, the heel region of the upper mid-layer is disposed in a heel cradle. The upper mid-layer may be supported on a board with its peripheral edge kept separate from the lower mid-layer. In one embodiment, the peripheral edges of the upper mid-layer and the lower mid-layer are separated by a heel portion or by both an arch portion and a heel portion.

In one embodiment, the peripheral edge of the plate flares outward to define a heel flange extending around at least a portion of the heel area of the plate. The heel flange may extend along a plane. The heel flange may include an upwardly facing surface that is exposed around at least a portion of the heel portion. In one embodiment, the upper mid-layer terminates on the lateral side, medial side, and rear end of the sole assembly short of the heel flange. In such embodiments, the upper mid-layer may be adhesively attached to the upper surface of the plate, excluding the upper side of the flange.

In one embodiment, the lower mid-bottom layer is wider than the upper mid-bottom layer in at least a portion of the heel region. In one embodiment, the lower mid-bottom layer extends below and in direct contact with the heel flange of the plate. Thus, the portion of the lower mid-bottom layer below the heel flange provides additional cushioning and support for the wearer's foot, particularly during heel strike.

In yet another embodiment, an outsole is disposed on the lower surface of the bottom mid-layer of the sole. If an outsole is included, the outsole may cover the entirety of the lower surface, or it may cover one or more portions of the lower surface. The outsole may be formed from a single continuous section of outsole material, or it may be formed from a plurality of separate sections of outsole material that cooperate to cover different portions of the lower surface. In some embodiments, the outsole (whether continuous or in separate portions) is secured to the lower surface of the bottom mid-layer of the sole by an adhesive.

In one embodiment, the peripheral edge of the bottom surface of the board is exposed in the arch area. For example, the bottom mid-layer may include medial and lateral recesses that expose portions of the bottom surface of the board. In some applications, the size and shape of the recesses may be selected to coordinate the cushioning, support, and energy return properties of the board, particularly in the arch area.

In yet another embodiment, the upper, top mid-bottom layer, plate and bottom mid-bottom layer may have a stepped arrangement in the heel portion, which is configured to provide the desired cushioning, support and energy feedback characteristics to the sole. In one embodiment, the top mid-bottom layer extends outwardly beyond the lateral range, medial range and rear range of the upper in the heel area. In one embodiment, the plate extends outwardly beyond the lateral range, medial range and rear range of the top mid-bottom layer. In one embodiment, the bottom mid-bottom layer extends outwardly beyond the lateral range, medial range and rear range of the top mid-bottom layer and/or plate in the heel area. The stepped arrangement provides a wide support for the heel on the lateral side, medial side and rear portion of the sole assembly, while reducing the width of the top mid-bottom layer to enhance the cushioning feel above the plate.

The present embodiment relates to a sole construction having a unique arrangement of a top mid-floor layer, a plate, and a bottom mid-floor layer that provides optimal support, cushioning, and energy return in the gait cycle from heel strike to toe-off. Among other things, the plate provides adequate longitudinal support for the forefoot while still allowing a desired amount of lateral flexibility. The use of a separate medial extension and a linked central extension and lateral extension gives the big toe enhanced independent flexibility while helping to maintain a higher level of lateral support for the remaining toes. The heel cradle helps center and support the wearer's foot and provides optimized energy return after heel strike. The combination of the stepped construction widens the ground engaging surface to provide enhanced support and cushioning. The heel flange extends outwardly above the widened bottom mid-floor layer to receive support and cushioning from additional cushioning material disposed thereunder.

These and other objects, advantages and features of the present invention will be more fully understood and appreciated by referring to the description of the current embodiments and the accompanying drawings.

Before explaining the embodiments of the present invention in detail, it should be understood that the present invention is not limited to the operational details or construction details, and the arrangement of the components described in the following description or shown in the drawings. The present invention can be implemented in various other embodiments, and can be implemented or executed in alternative ways that are not explicitly disclosed herein. In addition, it will be understood that the wording and terms used herein are for descriptive purposes and should not be considered as restrictive. The use of "comprising" and "including" and their variations is intended to cover the items listed hereafter and their equivalents, as well as additional items and their equivalents. Further, enumeration can be used for the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be regarded as limiting the present invention to any specific order or number of components. The use of enumeration should also not be regarded as excluding any additional steps or components that can be combined or combined with the steps or components listed from the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

1 is a perspective view of an article of footwear incorporating a sole according to an embodiment of the present invention.

FIG. 2 is a left side view of the sole assembly.

FIG. 3 is a right side view of the sole assembly.

FIG. 4 is an exploded view of the sole assembly.

5 is a top perspective view of the sole assembly.

FIG. 6 is a top perspective view of the board.

7 is a top perspective view of the bottom layer in the bottom portion.

8 is a cross-sectional view of the sole taken along line 8 - 8 of FIG. 2 .

9 is a cross-sectional view of the sole taken along line 9 - 9 of FIG. 2 .

10 is a cross-sectional view of the sole taken along line 10 - 10 of FIG. 2 .

11 is a cross-sectional view of the sole taken along line 11 - 11 of FIG. 2 .

FIG12 is a top plan view of the plate and bottom mid-layer with the top mid-layer removed; and

13 is a bottom plan view of the plate and top midlayer with the bottom midlayer removed.

Detailed ways

A footwear article according to the present embodiment of the present invention is shown in FIG. 1 and is generally designated as 10. The footwear article 10 includes a sole assembly 12 including a top midsole 14, a plate 16, and a bottom midsole 18. The sole assembly 106 may also include an outsole 50 joined to a bottom surface of the bottom midsole 18. The top midsole 14, the plate 16, and the bottom midsole 18 are configured to provide enhanced support, cushioning, and energy return. In this embodiment, the plate 16 includes a forefoot portion 20 having a medial extension 22, a central extension 24, and a lateral extension 26. The central extension 24 and the lateral extension 26 of this embodiment are joined to each other at their front ends by a bridge 28. The plate 16 also includes a heel portion 30, which includes a heel cup 32 and a peripheral heel flange 34. In this embodiment, the top midlayer layer 14 is secured within the heel cup 32 and does not extend beyond the heel flange 34 , while the bottom midlayer layer 18 is broader than the top midlayer layer 14 and extends beneath and supports the heel flange 34 .

Although the current embodiments are shown in the context of running shoes, the sole assembly thereof may be incorporated into any type or style of footwear, including performance shoes, off-road shoes and boots, work boots, all-terrain shoes, hiking shoes, athletic shoes, running shoes, basketball shoes, conventional tennis shoes, walking shoes, multisport footwear, casual shoes, dress shoes, or any other type of footwear or footwear component. It should also be noted that directional terms such as "vertical," "horizontal," "top," "bottom," "up," "down," "in," "inward," "outward," and "outward" are used to help describe the present invention based on the orientation of the embodiments shown in the accompanying drawings. Further, the terms "medial," "lateral," and "longitudinal" are used in a manner commonly used in conjunction with footwear. For example, when used to refer to the side of a shoe, the term "medial" is the side that points inward (i.e., the side that faces the other shoe), and "lateral" is the side that points outward. When used to refer to directions, the term "longitudinal direction" refers to a direction extending generally along the length of the shoe between the toe and the heel, and the term "lateral direction" refers to a direction extending generally across the width of the shoe between the medial and lateral sides of the shoe.

The use of directional terms should not be construed as limiting the present invention to any particular orientation. Further, as used herein, the term "arch region" (or arch or midfoot) generally refers to the portion of a footwear or sole assembly that corresponds to the arch or midfoot of a wearer's foot; the term "forefoot region" (or forefoot) generally refers to the portion of the footwear forward of the arch region, which corresponds to the forefoot of the wearer's foot (e.g., including the ball and toes); and the term "heel region" (or heel) generally refers to the portion of the footwear rearward of the arch region that corresponds to the heel of the wearer's foot. Forefoot region 100, arch region or midfoot region 102, and heel region 104 are generally identified in FIG. 1; however, the division of these regions may vary depending on the construction of the sole assembly and/or footwear.

The footwear 10 may include a textile upper 106 coupled to the sole assembly 12. The upper 106 may be formed of a variety of material elements that are coupled together to cover at least a portion of the wearer's foot. The material elements may be selected based on the intended use of the footwear 10 article and may include, for example, synthetic textiles, mesh textiles, polymers, or leather. The upper 106 may be configured to improve the stiffness of the sole assembly 12. For example, the upper may be made of leather, plastic, canvas, or other materials. The upper 106 may include one or more closure elements, such as shoelaces. The upper 106 also includes an upper opening for receiving the wearer's foot. The upper 106 may be attached to the sole assembly 12 using substantially any attachment form. For example, the bottom of the upper 106 may be closed by a Strobel plate (not shown) in a conventional manner, and the bottom edge of the sidewall of the upper 106 and the bottom surface of the Strobel plate may be fixed to the sole assembly 106 by an adhesive. The joining of sole component 12 and upper 106 may be accomplished using adhesives, cements, injection molding, cast molding, or any other technique for joining an upper and sole component.

An insole, inner sole, or footbed (not shown) may be positioned within the void defined by upper 106. The insole may be constructed from a sheet of material, such as foam, EVA, PU, latex, gel, or other material, and provides cushioning by virtue of its compressibility, and may also conform to the foot to provide comfort, support, and stability. The insole (not shown) need not be constructed from a sheet of material, but may instead be formed by other techniques, such as injection molding, compression molding, or additive manufacturing.

The sole assembly 12 will now be described in more detail with reference to FIGS. 2-12. FIGS. 2, 3 and 5 show the sole assembly 12 separated from the upper 106. As mentioned above, the sole assembly 12 of the illustrated embodiment includes a top midsole layer 14, a plate 16, a bottom midsole layer 18 and an outsole 50 (perhaps best shown in the exploded view of FIG. 4). The plate 16 is disposed between the top midsole layer 14 and the bottom midsole layer 18.

The top mid-layer 14 is configured to extend substantially the full length and width of the sole assembly 12 to provide a platform to receive and support the wearer's foot (directly or indirectly). In the illustrated embodiment, the upper surface 40 of the top mid-layer 14 is curved to provide a three-dimensional recess that is configured to receive the bottom of the upper 106 and provide a comfortable seat for the wearer's foot. The curvature can be selected to correspond to the shape of the bottom surface of the wearer's foot anatomically. In this embodiment, the peripheral boundary 42 of the top mid-layer 14 is raised above the bottom range of the upper 106. This allows the top mid-layer 14 to extend upward around the bottom of the upper 106 for a durable and aesthetically pleasing connection. The raised peripheral boundary 42 helps to center and keep the wearer's foot on the sole assembly 12. The thickness of the top mid-layer 14 can be varied to provide a desired support, cushioning and energy feedback profile. For example, in the illustrated embodiment, the top mid-layer layer 14 is thinner in the heel region 104 and gradually thickens through the arch region 102 into the forefoot region 100, wherein its maximum thickness is approximately at the center of the forefoot region 100, so that the top mid-layer layer 14 provides maximum cushioning beneath the metatarsal heads of the wearer's foot (see Figure 11).

In the illustrated embodiment, sole assembly 12 is configured to provide a support platform that is broader than the confines of upper 106. As shown in Figures 1, 5, 10, and 11, top midlayer layer 14 extends outwardly beyond the perimeter of upper 106 in heel region 104 on the lateral, medial, and rear portions of footwear 10. Additionally, bottom midlayer layer 18 extends beyond the perimeter of top midlayer layer 14 in the heel region on the lateral, medial, and rear portions of footwear 10.

As indicated above, plate 16 is disposed between top midsole layer 14 and bottom midsole layer 18 and is configured to provide desired support, cushioning, and energy return characteristics to sole assembly 12. Referring now to FIG. 6 , plate 16 generally includes a forefoot portion 20 extending through a forefoot region 100 of sole assembly 12, an arch portion 36 extending through an arch region 102 of sole assembly 12, and a heel portion 30 extending through a heel region 104 of the sole assembly. As shown, plate 16 may begin near the rearmost extension of sole assembly 12 and continue forward into forefoot region 100, terminating slightly short of the forward-most end of sole 12. Plate 14 includes a plurality of longitudinal extensions extending through forefoot region 100. The forefoot portion 20 of the plate 14 of the illustrated embodiment includes a medial extension 22 that extends longitudinally through the forefoot region 100 generally along the medial edge of the sole assembly 12, a central extension 24 that extends longitudinally through the approximate center of the forefoot region 100, and a lateral extension 26 that extends longitudinally in the forefoot region 100 along the lateral edge of the sole assembly 12. In this embodiment, the central longitudinal extension and the lateral longitudinal extension are joined to each other at their forward ends by a bridge 28.

In the illustrated embodiment, medial longitudinal extension 22 is curved and extends along the medial peripheral edge of sole assembly 12, starting at the front end of the arch region and extending forward at least to a point beneath a portion of the distal phalanx of the big toe (see FIGS. 8, 12, and 13). In one embodiment, medial longitudinal extension 22 may extend to a point beneath the phalanx, the proximal phalanx, or a point beneath the distal phalanx of the big toe. The configuration of medial longitudinal extension 22 may vary depending on the application. For example, the length, width, curvature, and thickness of medial longitudinal extension 22, as well as the offset from the medial edge of sole assembly 12, may vary.

The lateral longitudinal extension 26 of the illustrated embodiment is also curved in a manner similar to the medial longitudinal extension 22. As shown in Figures 8, 12 and 13, the lateral longitudinal extension 26 extends along the lateral peripheral edge of the sole assembly 12, starting at the front end of the arch area 102, and extending forward at least to a point below a portion of the middle phalanx of the 4th and/or 5th toes. In one embodiment, the lateral longitudinal extension 26 may extend to a point below the phalanx, proximal phalanx, middle phalanx or distal phalanx of the 4th and/or 5th toes. The configuration of the lateral longitudinal extension 26 may vary depending on the application. For example, the length, width, curvature and thickness of the lateral longitudinal extension 26, as well as the offset from the lateral edge of the sole assembly 12 may vary.

The central longitudinal extension 24 of the illustrated embodiment is generally straight, begins at the front end of the arch region 102, and extends forward at least to a point below a portion of the middle phalanx of the 2nd and/or 3rd toes (see FIGS. 8, 12, and 13). In this embodiment, the lateral bridge 28 extends between the front end of the central extension 24 and the lateral extension 26. In one embodiment, the central longitudinal extension 24 may extend to a point below the phalanx, proximal phalanx, middle phalanx, or distal phalanx of the 2nd and/or 3rd toes. The central longitudinal extension 24 may vary depending on the application. For example, the length, width, curvature, and thickness of the central longitudinal extension 24 may vary.

As discussed above, the illustrated plate 16 includes a bridge 28 connecting the central longitudinal extension 24 and the lateral longitudinal extension 26 to provide enhanced stability and support for the 2nd to 5th toes. In one embodiment, the bridge 28 may extend under the phalanges, proximal phalanges, middle phalanges, or distal phalanges of the 2nd to 5th toes. As shown, the central longitudinal extension 24, the lateral longitudinal extension 26, and the lateral bridge 28 cooperatively define the closed opening 44 in the forefoot region 100. The central longitudinal extension and the lateral longitudinal extension may be varied to vary the size, shape, and/or configuration of the closed opening 44.

Referring now to FIGS. 6 and 9-11, the heel portion 30 of the illustrated plate 16 is shaped to provide a heel cup 32. More specifically, the heel portion includes a gradually opening upward curve that helps to seat and center the wearer's foot on the sole assembly 12. In this embodiment, the arch portion 36 also curves upward in unison with the peripheral area of the heel portion 30, such that the heel portion 30 and the arch portion 36 cooperatively define an extended heel cup 32 that begins at the rear of the heel and extends fully into the arch region 102. The extent of the heel cup 32 may vary depending on the application.

Referring now to FIGS. 6, 10 and 11, an opening 46 is defined through the approximate center of the heel portion 30. The opening 46 may be generally oval in shape extending in the longitudinal direction. The heel opening 46 allows communication between the top midsole layer 14 and the bottom midsole layer 18 at the approximate center of the heel region 104, thereby providing enhanced centering and cushioning of the wearer's foot while also reducing the weight of the plate 16. The size, shape and configuration of the heel opening 46 may vary from application to application to coordinate the support, cushioning and energy return characteristics of the sole assembly 12. In some applications, the heel opening 46 may be eliminated.

In the illustrated embodiment, the peripheral edge of the plate 16 flares outward in the heel region 104 to define a heel flange 34 that extends around at least a portion of the heel region 30 of the plate 16. Perhaps as best shown in Figures 6, 10 and 11, the heel flange 34 of the illustrated embodiment extends along a plane and is generally crescent-shaped, but in alternative embodiments, it can be non-planar and have a different shape. In the illustrated embodiment, the heel portion of the top midsole layer 14 terminates short of the heel flange 34, thereby exposing the top surface of the heel flange 34. More specifically, as shown in Figures 5, 10 and 11, the illustrated heel flange 34 includes an upwardly facing surface that is exposed around at least a portion of the heel region 30 and a downwardly facing surface that is in direct contact with the bottom midsole layer 18, which will be discussed in more detail below.

In this embodiment, top midlayer layer 14 is adhesively bonded to the upper surface of plate 16, excluding the upper surface of heel flange 34 (which, as noted above, is exposed and not covered by top midlayer layer 16). Top midlayer layer 14 may also be adhesively bonded to the upper surface of bottom midlayer layer 14 in those areas where the bottom surface of top midlayer layer 14 and the surface of bottom midlayer layer 18 contact, such as through heel opening 46, around the perimeter of the forefoot area, and through the spaces between longitudinal extensions 22, 24, and 26. Top midlayer layer 14 and/or bottom midlayer layer 18 may be recessed to accommodate plate 16. For example, the bottom surface of top midlayer layer 14 may define a recess 70 corresponding to plate 16. In this embodiment, recess 70 is substantially coextensive with plate 16 and has substantially the same thickness as plate 16, such that the bottom surface of plate 16 is substantially flush with the bottom surface of top midlayer layer 14 around recess 70. In alternative applications, the plate 16 may be recessed in the bottom mid-layer 18 or in both the top mid-layer 14 and the bottom mid-layer 18. In alternative applications, the recess may be eliminated entirely.

In the illustrated embodiment, the bottom mid-layer 18 provides a cushioning, support and energy return layer for the sole assembly 12 that is generally disposed below the plate 16. Referring now to FIGS. 5 and 8-11, the bottom mid-layer 18 is positioned immediately below the plate 16. The bottom mid-layer 18 of the illustrated embodiment is wider than the top mid-layer 14 in at least a portion of the heel area. As shown, the bottom mid-layer 18 shown extends below and is in direct contact with the heel flange 34 of the plate 16. Thus, the portion of the bottom mid-layer 18 below the heel flange 34 provides additional cushioning, support and energy return that is generally transmitted through the plate 16.

As indicated above, the sole assembly 12 of the illustrated embodiment includes a stepped arrangement in the heel area 104. More specifically, the upper 106, top mid-layer 14, plate 16, and bottom mid-layer 18 of FIG. 1 are arranged in a stepped configuration, wherein each member is slightly wider than the member disposed above. The stepped heel configuration helps provide the sole with desired cushioning, support, and energy return properties. Referring now to FIG. 1 , the top mid-layer 14 extends outwardly beyond the lateral, medial, and rear ends of the upper 100 in the heel area 104. Similarly, the plate 16 of this embodiment extends outwardly beyond the lateral, medial, and rear ends of the top mid-layer 14 in the heel area 104. Further, the bottom mid-layer 18 of this embodiment extends outwardly beyond the lateral, medial, and rear ends of the top mid-layer 14 and/or plate 16 in the heel area 104. The degree of offset between the various layers of sole assembly 12 may vary depending on the application to provide the desired cushioning, support, and energy return characteristics.

In the illustrated embodiment, the peripheral edge of the bottom surface of plate 16 is exposed on both the lateral and medial sides in arch region 102. For example, bottom midlayer 18 may include medial and lateral recesses 48 that expose portions of the bottom surface of plate 18. The size, shape, and configuration of recesses 48 may be selected to coordinate the cushioning, support, and energy return characteristics of plate 16, particularly in arch region 102. More specifically, the characteristics of recesses 48 may be varied to coordinate the amount of cushioning material that engages and supports the plate in arch region 102.

In the illustrated embodiment, the bottom midlayer layer 18 may define a forefoot opening 60 that is disposed to extend through the bottom midlayer layer 18 from the bottom surface to the top surface. The forefoot opening 60 may be aligned with and extend along at least a portion of the central longitudinal extension 24. The forefoot opening 60 may reduce the support provided by the bottom midlayer layer 18 to the central longitudinal extension 24, thereby imparting additional flexibility to the central longitudinal extension 24 along its length. The size, shape, and configuration of the forefoot opening 60 may vary from application to application as desired to coordinate the characteristics of the sole assembly 12.

Similarly, bottom midlayer layer 18 may define an arch opening 62 that extends through bottom midlayer layer 18 in arch region 102. Arch opening 62 of the illustrated embodiment is generally triangular in shape and extends completely through bottom midlayer layer 18 from the bottom surface to the top surface such that plate 16 is visible through arch opening 62. In some applications, arch opening 62 helps control the amount of support and cushioning in arch region 102 and also provides a degree of separation between the forefoot and heel portions of bottom midlayer layer 18. The size, shape, and configuration of arch opening 62 may vary from application to application as desired to coordinate the characteristics of sole assembly 12.

In the illustrated embodiment, bottom midlayer layer 18 also defines a heel recess 64 that extends into the bottom of bottom midlayer layer 18 in heel region 104. The size, shape, depth, and configuration of heel recess 64 may vary from application to application to coordinate the characteristics of bottom midlayer layer 18 in heel region 104.

In this embodiment, bottom midlayer layer 18 is adhesively attached to the bottom surface of plate 16 and to the bottom surface of top midlayer layer 14. However, bottom midlayer layer 18 may be attached to sole assembly 12 using other methods. For example, plate 16 may be placed in a mold, and top midlayer layer 14 and/or bottom midlayer layer 18 may be molded in place on plate 16 as an integral part of the molding process.

As indicated above, in the illustrated sole assembly 12, the outsole 50 is disposed on the lower surface of the bottom mid-layer 18. When the outsole 50 is included, the outsole 50 may cover the entirety of the lower surface of the bottom mid-layer 18, or it may cover one or more different portions of the lower surface of the bottom mid-layer 18. The outsole may be formed from a single continuous section of outsole material, or it may be formed from a plurality of separate outsole material sections that cooperate to cover all or different portions of the lower surface. Referring now to FIGS. 2, 3, 8, 10 and 11, the outsole 50 includes a forefoot segment 52 and a heel segment 54. The illustrated forefoot segment 52 defines a central opening 56 that is aligned with the forefoot opening 60 in the bottom mid-layer 18 so that the central longitudinal extension 24 is visible from the bottom of the sole assembly 12.

In the illustrated embodiment, the outsole 50 (whether continuous or separate portions) is secured to the lower surface of the bottom midlayer 18 by adhesive. However, the outsole 50 may be attached to the lower surface using other methods. For example, the outsole 50 may be positioned in a mold when the bottom midlayer 18 is formed and thus attached as an integral part of the molding process.

The top mid-bottom layer 14 and the bottom mid-bottom layer 18 can be made of substantially any desired cushioning material. For example, the two mid-bottom layers can be made of ethyl vinyl acetate (EVA), polyurethane (PU), expanded thermoplastic polyurethane (eTPU) foam, polyether block amide (PEBA/PEBAX) foam, other beaded and non-beaded foams, gel or other cushioning materials. In the illustrated embodiment, the top mid-bottom layer 14 and the bottom mid-bottom layer 18 are made of eTPU or PEBA beaded foam. Although the top mid-bottom layer 14 and the bottom mid-bottom layer 18 are made of the same material in the illustrated embodiment, the two mid-bottom layers can be made of different materials or of the same material but with different cushioning properties (e.g., different hardness).

The plate 16 can be made of essentially any material, and is typically made of a material that is more rigid than the material used to make the mid-layer 14 and 18. In the illustrated embodiment, the plate 16 is made of nylon. For example, the plate 16 can be molded from nylon stock or formed from nylon sheets. Although the plate 16 of the illustrated embodiment is made of a single layer of material, the plate 16 can be made of multiple layers in alternative embodiments. For example, the plate 16 can be made of a composite material, such as a carbon fiber layer each woven from carbon filaments. It will also be appreciated that the plate can be made of other polymer materials, such as polymers, metals, composite materials, and combinations thereof.

Outsole 50 can be made of one or more materials, such as natural or synthetic rubber, thermoplastic polyurethane elastomer (TPU), nylon, polymer blends, wear-resistant polymers, elastomers and/or other materials. Other materials can be used, such as fiber-reinforced polymers, which may include epoxy resins, polyethylene or thermosetting plastics reinforced with carbon, glass and/or aramid fibers to enhance protection. Outsole 50 may include a plurality of lugs and/or treads extending downward or defined by a recess (the recess is recessed into the bottom surface of the outsole), or alternatively may be relatively featureless, thereby forming a smooth surface. Where present, lugs and treads may be arranged as desired, and alternatively arranged in a repeating pattern. Lugs and treads may include one or more geometric shapes.

Although various elements and assemblies of the embodiments are described herein as having certain functional properties, each element and/or its relationship to other elements may be described or oriented in a variety of different aesthetic configurations that support its decorative and aesthetic aspects. Just because a device, element, or assembly of one or more elements is described herein as having a function does not mean that its orientation, layout, or configuration is not purely aesthetic and decorative in nature.

In addition, when a member, part or layer is referred to as being "attached," "located at," "engaged," "adhered to," "fixed to," or "coupled to" another member, part or layer, it may be directly attached, engaged, adhered to, fixed to, or coupled to the other member, part or layer, or there may be any number of intervening members, parts or layers. In contrast, when an element is referred to as being "directly attached to," "directly located at," "directly engaged," "directly adhered to," "directly fixed to," or "directly coupled to" another element or layer, there may be no intervening elements or layers. Other words used to describe the relationship between members, layers, and parts should be interpreted in a similar manner, such as "adjacent" and "directly adjacent" and similar words. As used herein, the term "and/or" includes any and all combinations of one or more of the associated items listed.

The above description is a description of the current embodiment of the present invention. Various modifications and variations may be made without departing from the spirit and broader scope of the present invention as defined by the appended claims, which are interpreted according to the patent law principles including the principle of equivalents. The present disclosure is proposed for exemplary purposes and should not be interpreted as an exhaustive description of all embodiments of the present invention, or limiting the scope of the claims to the specific elements shown or described in conjunction with these embodiments. For example, without limitation, any independent element of the invention described may be replaced by an alternative element, which provides a substantially similar function or otherwise provides appropriate operation. This includes, for example, currently known alternative elements, such as those currently known to those skilled in the art, and alternative elements that may be developed in the future, such as those that may be considered as alternatives when developed by those skilled in the art. Further, the disclosed embodiments include a plurality of features that are consistently described and can collaboratively provide a series of benefits. The present invention is not limited to those embodiments that include all of these features or provide all of the benefits, unless otherwise explicitly set forth in the claims issued. Any reference to claim elements in the singular (e.g., using the articles "a," "an," "the," or "said") should not be construed as limiting the element to the singular. Any reference to claim elements "at least one of X, Y, and Z" is meant to include any one of X, Y, or Z, respectively, any combination of X, Y, and Z, such as X, Y, Z; X, Y; X, Z; and Y, Z, and/or any other possible combination of these elements together or separately, noting that they are open ended and may include other elements.

Claims (20)

1. A sole assembly, comprising: Top, middle and bottom layers; Bottom mid-bottom layer; and A plate is arranged between the top mid-layer and the bottom mid-layer, the plate including a heel portion, an arch portion and a forefoot portion, the forefoot portion including an inner longitudinal extension portion extending forward from the arch portion and having a free end opposite to the arch portion, a central longitudinal extension portion extending forward from the arch portion and having a free end opposite to the arch portion, and an outer longitudinal extension portion extending forward from the arch portion and having a free end opposite to the arch portion, the central longitudinal extension portion and the outer longitudinal extension portion being connected to each other by a bridge extending between the free end of the central longitudinal extension portion and the free end of the outer longitudinal extension portion. 2. The sole assembly of claim 1, wherein the plate comprises a heel cup disposed at least in the heel portion, the heel cup being curved and open upwardly. 3. The sole assembly of claim 2, wherein the plate includes a heel flange extending outwardly from the heel cup at least in the heel portion. 4. The sole assembly of claim 3, wherein the top midsole layer does not cover the heel flange. 5. The sole assembly of claim 3, wherein the bottom midsole layer is located below the heel flange. 6. The sole assembly of claim 5, wherein the sole assembly includes a heel region, and wherein the top midsole layer and the bottom midsole layer are stepped, wherein the bottom midsole layer extends beyond the medial extent, lateral extent, and rear extent of the top midsole in the heel region. 7. The sole assembly of claim 6, wherein the heel flange is crescent-shaped and generally planar. 8. The sole assembly of claim 7, wherein the bottom midsole defines a lateral recess and a medial recess that expose portions of the lower surface of the plate in the arch region. 9. The sole assembly of claim 8, wherein the bottom midsole layer defines a forefoot opening below a portion of the central longitudinal extension, the forefoot opening extending through the bottom midsole layer to expose at least a portion of a lower surface of the central longitudinal extension. 10. The sole assembly of claim 1, wherein the medial longitudinal extension is offset inwardly from a medial edge of the sole assembly, the medial longitudinal extension being curved corresponding to the medial edge; and wherein the lateral longitudinal extension is offset inwardly from the lateral edge of the sole assembly, and the lateral longitudinal extension is curved corresponding to the lateral edge; and Wherein, the central longitudinal extension is substantially straight and is disposed between the inner and outer longitudinal extensions and the outer longitudinal extensions. 11. A footwear article comprising: an upper having a heel portion, an arch portion, and a forefoot portion; and A sole assembly connected to the upper, the sole assembly comprising: a top mid-bottom layer having a heel portion, an arch portion, and a forefoot portion; a bottom midsole layer having a heel portion, an arch portion, and a forefoot portion; and A plate disposed between the top mid-layer and the bottom mid-layer, the plate having a heel portion having a heel cup and a peripheral flange extending from at least a portion of the heel cup, the plate having an arch portion extending forward from the heel portion, the plate having a forefoot portion having a medial longitudinal extension extending forward from the arch portion, a central longitudinal extension extending forward from the arch portion, and a lateral longitudinal extension extending forward from the arch portion and having a free end opposite the arch portion, the central longitudinal extension and the lateral longitudinal extension being connected to each other by a bridge extending between the free end of the central longitudinal extension and the free end of the lateral longitudinal extension, the plate having a bridge extending between the central longitudinal extension and the lateral longitudinal extension. 12. The footwear of claim 11, wherein the heel portion of the top midsole layer extends outwardly beyond the heel portion of the upper on the lateral, medial, and rear portions of the upper; Wherein, the heel portion of the bottom midsole layer extends outwardly beyond the heel portion of the top midsole layer on the lateral side, medial side and rear portion of the upper. 13. The footwear of claim 12, wherein a heel portion of the top midsole layer is seated within the heel cup; and The heel flange includes a top surface not covered by the top midsole layer and a bottom surface engaged with the bottom midsole layer. 14. The footwear of claim 13, wherein the heel flange is crescent-shaped and generally planar. 15. The footwear of claim 14, wherein the bottom midsole layer defines a lateral recess and a medial recess that expose a portion of a lower surface of an arch portion of the plate. 16. The footwear of claim 15, wherein the bottom midsole layer defines a forefoot opening below a portion of the central longitudinally extending portion, the forefoot opening extending through the bottom midsole layer to expose at least a portion of a lower surface of the central longitudinally extending portion. 17. The footwear of claim 16, wherein the heel portion of the plate defines a central opening, the top midsole layer communicating with the bottom midsole layer through the central opening. 18. The footwear of claim 17, wherein the medial longitudinal extension is offset inwardly from a medial edge of the sole assembly, the medial longitudinal extension being curved and extending generally parallel to the medial edge; and wherein the lateral longitudinal extension is offset inwardly from a lateral edge of the sole assembly, the lateral longitudinal extension being curved and extending generally parallel to the lateral edge; and Wherein, the central longitudinal extension is substantially straight and is disposed between the inner outer extension and the outer longitudinal extension. 19. The footwear of claim 18, wherein the medial longitudinal extension extends along a medial edge of the sole assembly in a position supporting a big toe of a wearer's foot, and wherein the bridge extends laterally across the sole assembly in a position supporting a second through fifth toes of the wearer's foot. 20. The footwear of claim 19, further comprising an outsole having a forefoot segment and a heel segment, the forefoot segment defining a forefoot opening that coincides with the forefoot opening of the bottom midsole.