U.S. patent application number 11/754509 was filed with the patent office on 2007-12-06 for removable footwear cleat with cushioning.
Invention is credited to Jeffrey M. Dow, Craig Rubino, Armand J. Savoie.
Application Number | 20070277399 11/754509 |
Document ID | / |
Family ID | 38537887 |
Filed Date | 2007-12-06 |
United States Patent
Application |
20070277399 |
Kind Code |
A1 |
Dow; Jeffrey M. ; et
al. |
December 6, 2007 |
Removable Footwear Cleat with Cushioning
Abstract
A removable cleat for footwear. The cleat includes a disc with
opposing faces. A shoe coupling element is attached to one face of
the disc. The other disc face supports a cushioning layer. Traction
elements are supported by the cushioning layer. When a user steps
on a surface wearing a shoe outfitted with these cleats, the
resilience of the cushioning layer at once both lessens the impact
of the traction elements on the ground surface and lessens the
reaction force on the user's foot transmitted through the shoe's
outsole. The user's comfort is thereby enhanced.
Inventors: |
Dow; Jeffrey M.; (Paxton,
MA) ; Rubino; Craig; (Brighton, MA) ; Savoie;
Armand J.; (Gardner, MA) |
Correspondence
Address: |
BROMBERG & SUNSTEIN LLP
125 SUMMER STREET
BOSTON
MA
02110-1618
US
|
Family ID: |
38537887 |
Appl. No.: |
11/754509 |
Filed: |
May 29, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60809323 |
May 30, 2006 |
|
|
|
60823396 |
Aug 24, 2006 |
|
|
|
Current U.S.
Class: |
36/134 |
Current CPC
Class: |
A43C 13/04 20130101;
A43C 15/168 20130101 |
Class at
Publication: |
036/134 |
International
Class: |
A43B 5/00 20060101
A43B005/00 |
Claims
1. A removable cleat for a shoe for a user, the cleat comprising: a
disc including opposing first and second faces; a shoe attachment
element attached to the first face of the disc; a cushioning layer;
and at least one traction element, wherein the cushioning layer is
located between the second face of the disc and the at least one
traction element.
2. A cleat according to claim 1, further including a plurality of
cleat wrench attachment structures, the structures attached to the
second face of the disc.
3. A cleat according to claim 2, wherein the cleat wrench
attachment structures are generally cylindrical and extend through
the cushioning layer.
4. A cleat according to claim 1, wherein the cushioning layer is
bonded to the second face of the disc.
5. A cleat according to claim 1, wherein the traction element is
bonded to the cushioning layer.
6. A cleat according to claim 1, wherein the cushioning layer
includes at least one cutout.
7. A cleat according to claim 1 wherein the at least one traction
element is positioned to substantially prevent the cushioning layer
from contacting a ground surface, when the cleat installed in a
shoe.
8. A cleat according to claim 1, wherein a plurality of traction
elements directly engage the cushioning layer.
9. A cleat according to claim 1, wherein the second face of the
disc further includes a raised portion to serve as a wear
indicator.
10. A cleat according to claim 9, wherein the raised portion of the
disc face differs in color from the at least one traction
element.
11. A cleat according to claim 1, wherein the durometer of the
cushioning layer ranges from Shore 10A to Shore 50A.
12. A cleat according to claim 1, wherein the durometer of the at
least one traction element is in the range from Shore 60A to Shore
98A.
13. A cleat according to claim 1, wherein the difference in
durometer of the at least one traction element and a portion of the
cushioning layer ranges from about 20 to about 70 on the Shore
scale.
14. A cleat according to claim 1, wherein the durometer of the
cushioning layer is less than the durometer of the at least one
traction element and the durometer of the cushioning layer is less
than the durometer of the disc.
15. A removable cleat according to claim 1, wherein the cushioning
layer is more resilient that both the at least one traction element
and the disc.
16. A cleat according to claim 1, wherein the at least one traction
element includes: a hub, at least one spoke connected to the hub,
and a specified traction element connected to the spoke at a spoke
end distal to the hub.
17. A cleat according to claim 14, wherein the specified traction
element connected to the spoke is shaped as a tooth.
18. A cleat according to claim 14, wherein the specified traction
element connected to the spoke is generally frusto-conical in
shape.
19. A cleat according to claim 1, wherein the cushioning layer
further includes a debris skirt such that when the cleat is
securely attached to footwear, the debris skirt substantially
prevents debris from moving towards the shoe attachment
element.
20. A removable cleat according to claim 19, wherein at least a
portion of the debris skirt compresses when the cleat is securely
attached to footwear.
21. A removable cleat according to claim 20, wherein at least a
portion of the debris skirt folds when the cleat is securely
attached to footwear.
22. A removable cleat for a shoe for a user, the cleat comprising:
a disc including opposing first and second faces; a shoe attachment
element attached to the first face of the disc; and at least one
traction element directly engaging the second face of disc, the
second face of the disc including a center, wherein the traction
element includes cushioning material inserted into slots formed in
a face of the at least one traction element.
23. A cleat according to claim 22, wherein the face of the at least
one traction element including cushioning material generally faces
the center of the disc.
24. A cleat according to claim 22, wherein the face of the at least
one traction element that includes cushioning material generally
faces away from the center of the disc.
25. A removable cleat for a shoe for a user, the cleat comprising:
a disc including opposing first and second faces; a shoe attachment
element attached to the first face of the disc; an intermediate
layer; and at least one traction element, wherein the intermediate
layer is located between the second face of the disc and the at
least one traction element and the intermediate layer is softer
than both the at least one traction element and the disc.
26. A removable cleat according to claim 25, wherein the
intermediate layer is more resilient that both the at least one
traction element and the disc.
27. A removable cleat for footwear, the cleat comprising: a disc
including opposing first and second faces; a shoe attachment
element connected to the first face of the disc; a cushioning
layer; a traction element for providing traction on a surface; a
connector for mechanically attaching the traction element to at
least one of the disc and the shoe attachment element, wherein the
cushioning layer is located between the disc and the at least one
traction element.
28. A removable cleat according to claim 27, wherein the connector
is a press-fit coupler.
29. A removable cleat according to claim 27, wherein the connector
is a rivet.
30. A removable cleat according to claim 27, wherein the connector
includes a coupler that rotates to attach the traction element to
the disc.
31. A removable cleat according to claim 27, wherein the connector
is part of the traction element.
32. A removable cleat according to claim 27, wherein the traction
element is further attached to the disc with a non-mechanical
connection.
33. A removable cleat according to claim 32, wherein the traction
element folds over between the non-mechanical connection and the
mechanical connection.
34. A removable cleat according to claim 32, wherein the traction
element includes a male connector and the disc includes a female
connector.
35. A removable cleat according to claim 32, wherein the traction
element includes a female connector and the disc includes a male
connector.
Description
[0001] This application claims priority from U.S. provisional
patent application Ser. No. 60/809,323, filed May 30, 2006,
entitled "Removable Footwear Cleat with Cushioning," which is
incorporated herein by reference. This application also claims
priority from U.S. provisional patent application Ser. No.
60/823,396, filed Aug. 24, 2006, also entitled "Removable Footwear
Cleat with Cushioning," which is incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present invention relates to traction cleats mounted on
the bottom of footwear, in particular, on the bottom of athletic
footwear.
BACKGROUND
[0003] Athletic shoe cleats, in particular golf cleats, have been
subject to changing designs in recent years, to attempt to provide
users with a variety of advantages. For many years, a cleat took a
simple form of a spike, usually made of metal, attached to the
bottom of a shoe. Because such spikes could damage non-athletic
surfaces and some athletic surfaces as well, variations have been
made from the simple form. For example, UK Patent Application
2,098,457 to Perks discloses surrounding a spike element of a cleat
with soft material, to decrease damage done to surfaces.
SUMMARY OF THE INVENTION
[0004] In an embodiment of the invention, a removable cleat for an
article of footwear is provided. The cleat includes a disc with
opposing faces. One face of the disc includes a shoe attachment
element for removably attaching the cleat to the footwear's
outsole. A cushioning layer directly engages the second face of the
disc and a traction element directly engages the cushioning layer,
forming a "sandwich." The traction element provides secure footing
when installed in footwear. The cushioning layer affords resilient
backing to the traction element, enhancing user comfort. The
traction element provides a durable covering for at least a portion
of the cushioning layer, extending the life of the cleat.
[0005] In another embodiment of the invention, a removable cleat
for a shoe is provided. The cleat includes a disc with opposing
faces. A shoe attachment element is connected to one face of the
disc. At least one traction element directly engages the second
face of the disc. The traction element includes cushioning material
formed in one or more faces of the traction element. In some
embodiments, a face with cushioning material is oriented towards
the center of the disc and, in other embodiments, a face with the
cushioning material is oriented away from the center of the disc.
In further embodiments, the cleat includes a mix of traction
elements with each type of face. In yet another embodiment, the
cleat includes traction elements with cushioning material embedded
into more than one face of the traction element.
[0006] In another embodiment of the invention, a removable cleat
for a shoe is provided. The cleat includes a disc with opposing
faces, with a shoe attachment element connected to one face of the
disc. The shoe attachment element removably attaches the cleat to
the outsole of the shoe. A cushioning layer includes opposing faces
with at least a portion of one face of the cushioning layer
directly engaging the surface-facing face of the disc. The
cushioning layer further including a debris skirt, such that when
the cleat is securely attached to footwear, the debris skirt
substantially prevents debris from moving towards the shoe
attachment element. At least one traction element directly engages
the surface-facing face of the cushioning layer and provides secure
footing for the shoe wearer. In some embodiments of the invention,
the shape of the debris skirt provides additional cushioning to the
traction element, when the debris skirt deflects under pressure
from the weight of the wearer. The debris skirt may be made with
folds, like an accordion or bellows, to provide such cushioning
deflection.
[0007] In a further embodiment of the invention, a removable cleat
for a shoe is provided. The cleat includes a disc with opposing
faces. A shoe attachment element is connected to one face of the
disc and a traction element or traction element assembly also
attaches mechanically to the disc. This method of attaching
traction elements to the cleat disc provides a wider choice of
materials for the cleat, than is possible with conventional bonded
connections. The mechanical connection between traction element and
cleat disc may be provided with a press-fit coupler or a rivet or a
connector that rotates to attach the traction element to the disc.
The mechanical connector between traction element and disc may be
provided as a separable component or may be formed as part of a
traction element or traction element assembly. In some embodiments,
the traction element is formed with one part of the element
attached to the cleat disc and a second part formed as a coupler.
The traction element can fold over and mate with a corresponding
coupler embedded in the cleat disc. The flex of the folded-over
traction element provides a cushioning effect for the wearer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing features of the invention will be more readily
understood by reference to the following detailed description,
taken with reference to the accompanying drawings, in which:
[0009] FIG. 1 is an exploded view of a removable cleat for
footwear, according to an embodiment of the invention;
[0010] FIG. 2 includes several additional views of the cleat of
FIG. 1;
[0011] FIG. 3 is a sectional view of a removable cleat for an
alternative embodiment of the invention;
[0012] FIG. 4 is another sectional view of the cleat of FIG. 3;
[0013] FIG. 5 shows the ground contacting face of the cleat of FIG.
3;
[0014] FIGS. 6A-6B illustrate an alternative embodiment of the
invention that includes cushioning material embedded in traction
elements;
[0015] FIGS. 6C-6D illustrate another embodiment of the invention
that includes cushioning material embedded in traction
elements;
[0016] FIGS. 7A shows a view of the ground-engaging face of a cleat
with a debris skirt, in an embodiment of the invention;
[0017] FIG. 7B shows a view from the shoe-attachment side of the
cleat of FIG. 7A;
[0018] FIG. 8 shows a cutaway view of a section of the cleat of
FIG. 7A;
[0019] FIGS. 9A-9B illustrate the reaction of the debris skirt to
pressure from the adjacent traction element for the cleat of FIG.
7A;
[0020] FIG. 10 shows a cleat with a debris skirt that folds,
according to an embodiment of the invention;
[0021] FIG. 11 shows a cutaway view of a section of the cleat of
FIG. 10;
[0022] FIG. 12A shows a cleat with a hollow cushioning layer
supporting a traction element, according to an embodiment of the
invention;
[0023] FIG. 12B shows a cutaway view of a section of the cleat of
FIG. 12A;
[0024] FIG. 13 shows an exploded view of a cleat with a traction
element with an integral mechanical coupler, according to an
embodiment of the invention;
[0025] FIG. 14 shows a view of the cleat of FIG. 13, assembled;
[0026] FIG. 15 shows the cleat of FIG. 13 in a cutaway side view,
assembled;
[0027] FIG. 16 shows a cleat with a rivet fastener holding folding
traction elements to a cleat disc according to an embodiment of the
invention;
[0028] FIG. 17 shows a procedure for assembling the cleat of FIG.
16; and
[0029] FIG. 18 shows an alternative approach to fastening folding
traction elements to a cleat disc in an embodiment of the
invention.
DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
[0030] Definitions. As used in this description and the
accompanying claims, the following terms shall have the meanings
indicated, unless the context otherwise requires:
[0031] A "shoe" means any outer covering for a foot including,
without limitation, athletic footwear, sandals, boots, and
slippers.
[0032] A "disc" means any object with opposing, generally planar
faces. A disc can include concave portions or convex portions or
combinations of concave and convex portions. Discs are not limited
to circular shapes but may be, for example, elliptical, triangular,
rectangular, or even irregular shapes, etc.
[0033] In various embodiments of the present invention, a removable
footwear cleat comprises a shoe attachment portion, a cushioning
layer directly engaging the shoe attachment portion and a traction
element assembly, positioned on the cushioning layer. Thus, the
cleat forms a "sandwich." The shoe attachment portion includes a
disc with opposing faces. One face of the disc includes a shoe
attachment element that removably attaches the cleat to a
corresponding element (i.e., receptacle) in a shoe outsole. A
second face of the disc supports the cushioning layer. When a user
steps on a surface wearing a shoe outfitted with these cleats, the
resilience (i.e., "give") of the cushioning layer at once both
lessens the impact of the traction elements on the ground surface
and lessens the reaction force on the user's foot, as transmitted
through the shoe's outsole. The user's comfort is thereby
enhanced.
[0034] In an embodiment of the invention, as shown in the exploded
view of FIG. 1, a removable cleat 10 consists of a "sandwich"
comprising a shoe attachment portion 20, a cushioning layer 30 and
a traction element assembly 40. The shoe attachment portion 20
supports the cushioning layer 30. The traction element assembly 40
is installed on the surface (or in the surface) of the cushioning
layer 30. FIG. 2 shows a plan view of the cleat of FIG. 1 from the
top, along with two sectional views.
[0035] Referring to FIG. 1, the shoe attachment portion 20 of the
cleat includes a disc 24 with opposing faces. A male shoe
attachment element 22 is coupled to a first face of the disc 24.
The shoe attachment element may be formed according to any design
known in the art, such as Macneill Engineering's Q-LOK.TM. system,
which is described in U.S. Pat. No. 5,768,809, which patent is
incorporated herein by reference. The second face 26 of the shoe
attachment disc 24 includes two or more cleat wrench pin shafts 60,
formed typically as hollow cylinders, extending away from the disc
face 26. These shafts 60 allow a cleat wrench to attach temporarily
to the cleat for removably attaching the cleat to a shoe outsole.
The user inserts the prongs of a cleat wrench into the wrench pin
shafts and applies torque to the wrench to rotate the cleat.
Insertion of the shoe attachment element 22 into a matching
receptacle (not shown) in the shoe outsole, followed by rotation of
the cleat, attaches the cleat to the outsole. These wrench pin
shafts extend through the cushioning layer of the cleat and through
the traction element assembly to the surface of the ground-engaging
face of the cleat. This construction avoids attaching the cleat
wrench to either the traction element assembly or to the cushioning
material. The former is likely to twist as torque is applied by the
wrench while the latter is too soft to transfer torque to the shoe
attachment element of the cleat effectively.
[0036] In some embodiments of the invention, the second face of the
disc 26 (i.e. ground-facing face) includes one or more raised
portions 61. This raised portion 61 is located below the
ground-engaging surface of the cleat, when the cleat is complete.
In preferred embodiments, this raised portion may be attached to
the center of the ground-facing disc face 26. This raised portion
can serve as a wear indicator. When the ground-engaging surface
(i.e. traction element assembly 40) of the cleat has worn away
sufficiently, the wear indicator is exposed as a sign to the user
that the cleat should be replaced. The color of the wear indicator
may contrast with the color of traction elements to provide a
visible sign to the user that the ground-engaging surface of the
cleat has worn away.
[0037] The ground-facing face 26 of the cleat disc 24 supports the
cushioning layer 30 of the cleat 10. The cushioning layer provides
resilience or "bounce" to the cleat. The cushioning layer may be
made of plastic or rubber or another compressible material. In
specific embodiments of the invention, the cushioning layer
material preferably ranges in durometer from Shore 10A to Shore
50A. In some embodiments, the cushioning layer may take on a
regular, convex shape. (See FIG. 5, cushioning layer 40, for
example, where the cushioning layer is formed as a disc). In other
embodiments, the cushioning layer may include one or more cutouts
or notches. (See, for example, FIG. 1 where cushioning layer 30
includes six regularly spaced cutouts 42.) The cushioning material
can expand into the space formed by these cutouts 42 as the
traction elements above the cushioning layer make ground contact,
compressing the cushioning layer. The resilience or bounce provided
by the cushioning layer to the shoe attachment element and the
traction elements is thereby enhanced.
[0038] The traction element assembly 40 of the cleat engages the
ground surface, providing traction for the user. The traction
element assembly of the cleat may be formed with traction elements
in a variety of shapes and sizes and with various materials. The
traction element assembly 40 provides protection for the relatively
softer cushioning layer 30, as the cleat contacts the ground
surface. Note that the term "traction element assembly" does not
imply that all of the traction elements are necessarily connected
in each embodiment of the invention. Some, all or none of the
elements may be connected together in a traction element
assembly.
[0039] In the embodiment of the invention shown in FIGS. 1 and 2,
the traction element assembly consists of six traction teeth 54
connected to a central hub 51 by individual spokes 52. This
traction element assembly structure allows each traction tooth (and
spoke) to flex independently of each other tooth and spoke when
contacting the ground surface. The cushioning layer supports and
cushions each traction tooth independently of each other traction
tooth. The cushioning layer provides the restoring force to return
the traction tooth and spoke to its original position, as a cleat
traction tooth leaves the ground surface as the wearer walks. The
cushioning layer will flex into the space between the spokes as the
spokes move. The traction teeth at the ends of the spokes (which
spokes are also known as flex beams) are the primary traction
points for the cleat. In various specific embodiments of the
invention, these teeth can be of any shape (conical, square,
pyramidal, frusto-conical, etc), of any length or height, and may
have any shape tip (pointed, blunt, domed, slanted inward, slanted
outward, etc). The number of teeth at the end of a spoke is
variable and the number of spokes connected to a disc may number
more or less than six. The axis of each tooth is preferably
oriented at a maximum of 90 degrees to the plane of the cleat
(i.e., to the plane of the outsole when installed), or may be
substantially less than 90 degrees (e.g., angled toward the center
of the disc). The hub at the center of the traction element
assembly may be solid or the hub may have an opening to accommodate
a wear indicator or to allow material in the cushioning layer to
flex through the opening. In a preferred embodiment of the
invention, a plurality of such cleats is provided on a shoe
outsole. The independent flexing of the traction elements within a
cleat and across the plurality of cleats supplies traction that
adapts well to uneven surfaces.
[0040] In embodiments of the invention, the durometer of the
traction elements ranges preferably from about Shore 60A to about
Shore 98A. In specific embodiments of the invention, the traction
elements are formed from a thermoplastic material, such as
polyurethane. In some embodiments of the invention, the traction
elements are each similar in construction and arranged in a
symmetrical pattern around the perimeter of the cushioning layer.
In other embodiments, the traction elements may differ in size,
shape, and/or material and may be placed asymmetrically with
respect to the perimeter of the cushioning layer. In each
embodiment, the cushioning material provides resilient backing for
the harder traction element assembly positioned on it when the user
puts weight on the cleat through the shoe outsole. The disc, being
formed of a material that is less resilient than the cushioning
layer, provides support for the cushioning layer. The traction
element assembly may be formed to fully cover the cushioning layer,
providing a high level of protection for the cushioning layer from
surface contact, or may cover only a portion of the cushioning
layer. As described above, the cushioning layer may include notches
that allow the cushioning material to expand into the notches as
the traction elements apply pressure to the cushioning layer. These
notches can also allow the traction elements to twist from
side-to-side as the cushioning material flexes to fill the notches.
This traction element twisting action can provide for enhanced
traction on uneven surfaces.
[0041] In preferred embodiments of the invention, the cushioning
layer material and the traction element assembly material are
matched so that the difference in durometer between the cushioning
layer and the traction element assembly ranges from about 20 to
about 70 points on the Shore durometer scale. In various
embodiments of the invention, the materials may be tailored for
factors such as the characteristics of the shoe wearer or the
characteristics of the ground surface. For example, a heavier
player may be provided with a cleat with a cushioning layer
material that is (relatively) harder, coupled with a
correspondingly harder traction element material. A smaller or
lighter weight player may be provided a cleat with corresponding
softer elements. As a second example, for play on dry, hard, firm
ground a cleat with a larger spread between the hardness of the
cushioning layer and the traction element assembly may be provided.
For play on wet or soft ground, a cleat with a smaller spread
between the hardness of the elements may be advantageously
employed.
[0042] FIGS. 3-5 show another illustrative embodiment of the
invention. This embodiment is similar to the embodiment shown in
FIGS. 1-2, except that the cushioning layer is formed as a disc
without notches. (A common numbering scheme is used for the
features in FIGS. 3-5 and in FIGS. 1-2).
[0043] In another embodiment of the invention, as shown in FIGS. 6A
and 6B, a cleat includes traction elements (110, 115) connected
directly to the second face (ground-engaging face) 120 of a shoe
attachment portion disc 120. FIG. 6A is a perspective view of the
ground-engaging face of the cleat. The cushioning material 125 is
inserted into slots formed in a face of traction elements 110. This
face of the traction element faces the center of the ground-facing
face 120 of the disc. FIG. 6B shows a traction element 110 in cross
section with the cushioning material 125 on the traction element
face. The elastic nature of the cushioning material provides a
restoring force as a traction tooth compresses the cushioning
material under the weight of a user. Likewise, if the traction
element 110 is twisted away from the center of the cleat disc, the
elasticity of the cushioning material will provide a restoring
force, tending to return the traction element to its upright
position.
[0044] In a further related embodiment, as shown in FIGS. 6C and
6D, a cleat 200 includes traction elements (210, 215) connected
directly to the second face (ground-facing face) of a shoe
attachment portion disc (not shown). Traction elements 210 include
cushioning material 225 inserted into slots formed in the face of
traction elements 210, as shown in FIG. 6D. This face of the
traction element faces away from the center of the ground-facing
face of the cleat disc. The elastic nature of the cushioning
material provides a restoring force as the traction teeth compress
the cushioning material under the weight of a user. Likewise, if
the traction element 210 is twisted inward toward the center of the
cleat, the elasticity of the cushioning material will provide a
restoring force, tending to return the traction element to its
original orientation.
[0045] In other embodiments of the invention, a traction element
may be provided with the cushioning material embedded into any face
of the traction element. Further, a traction element may have
cushioning material embedded into more than one face of the
element. For example, a traction element may have cushioning
material embedded into two faces of the element with one face
oriented towards the center of the cleat disc and another face
oriented away from the center of the disc. The traction elements
for a cleat may be all of a common type or may include any mix and
placement of traction elements with different patterns of
cushioning material in traction element faces.
[0046] Debris Skirt
[0047] In other embodiments of the invention, a removable footwear
cleat includes a cushioning layer with a debris skirt. The debris
skirt prevents dirt, grass and other material from entering and
clogging the space between the cleat and outsole of a shoe. The
cleat comprises a shoe attachment portion; a cushioning layer
directly engaging the shoe attachment portion; and a traction
element assembly, positioned on the cushioning layer. The shoe
attachment portion includes a disc with opposing faces. One face of
the disc includes a shoe attachment element that removably attaches
the cleat to a corresponding element (e.g., receptacle) in a shoe
outsole. The opposing face of the disc supports the cushioning
layer. The perimeter of the cushioning layer includes a debris
skirt. When installed on the shoe, the skirt extends toward the
outsole of the shoe. When the cleat is fully engaged with the
receptacle, the skirt contacts the outsole, forming a barrier to
debris. The structure of the cushioning layer between the skirt and
the second face of the disc can allow the debris skirt to deflect
when pressure from ground contact forces the traction element into
the cushioning layer. Such debris skirt deflection increases the
resiliency of the cushioning layer at the layer's perimeter,
enhancing user comfort and protection of the turf surface.
[0048] An example of a cleat 700 with a debris skirt is shown in
FIG. 7, according to an embodiment of the invention. FIG. 7A shows
a perspective view of the ground engaging face of the cleat 700. A
plurality of traction elements 704 are connected via spokes to a
center hub 751, forming a traction element assembly. The traction
element assembly engages a cushioning layer 706. The cushioning
layer includes a skirt 708 which extends upwards and typically
contacts the shoe outsole, when the cleat is installed in the shoe.
A cleat wrench can engage pin shafts 710 in the ground engaging
face of the cleat to install the cleat into the shoe. FIG. 7B shows
a perspective view of the shoe attachment portion of the cleat 700.
The shoe attachment portion includes a disc 714 with opposing
faces, one face of which is visible in FIG. 7B, and a male shoe
attachment element 712. The shoe attachment element 712 is inserted
into a receptacle in the shoe outsole and rotated to attach the
cleat to the shoe. The shoe attachment face of the disc 714
includes a perimeter 718, which, in this embodiment, is generally
circular. The cushioning layer 706 includes a hollow portion 716
between the disc perimeter 718 and debris skirt 708. FIG. 8 shows a
cutaway perspective view of the structure of the cleat 700 from the
ground engaging side of the cleat. As shown in FIG. 9, when
pressure is applied to a traction element 704 by contact with the
ground surface, the debris skirt bends upward toward the shoe. The
hollow 716 behind the debris skirt allows the portion of the skirt
which contacts the outsole to slide outwardly from the disc's
center. The debris skirt at once prevents debris from migrating
towards the shoe attachment element of the cleat and provides
additional cushioning to the traction element as the bottom of the
skirt slides outwardly.
[0049] In a related specific embodiment of the invention, the outer
perimeter 1006 of the cushioning layer of a cleat 1000 forming the
debris skirt may include folds, like an accordion or bellows, as
shown in FIG. 10. As illustrated in FIG. 11, the folds allow the
outer face of the cushioning layer to resiliently deflect upwards
towards the shoe when pressure is applied to a traction element
1004. The folds permit the face of the cushioning layer to bend
upward towards the outsole without deflecting substantially outward
from the center of the disc.
[0050] In another specific embodiment of the invention, as shown in
FIG. 12, the cushioning layer of the cleat 1200 may include cutouts
such that the cushioning layer is not rotationally symmetrical
about the axis of the shoe attachment element (not shown) of the
disc 1214. As described previously, this arrangement allows the
cushioning material to expand into the cutouts as pressure is
applied to the traction elements 1204 and spokes 1252 of the
traction element assembly, enhancing the cushioning effect. A
cavity 1216 is provided behind the outer perimeter 1208 of the
cushioning layer 1206. This cavity can trap air which provides an
additional cushioning effect as pressure is applied to the traction
element above the cavity. The air trapped in the cavity 1216 by the
outsole of the shoe can escape relatively slowly providing an
additional measure of resiliency for the traction element assembly.
While three cutouts (and spokes) are shown for this embodiment, any
number of spokes and cutouts can be employed in various embodiments
of the invention.
[0051] Mechanical Attachment of Traction Elements to Cleat
[0052] In other embodiments of the invention, traction elements or
a traction element assembly are attached mechanically to the shoe
attachment portion of a cleat. The shoe attachment portion of the
cleat comprises a disc with opposing faces attached to a shoe
attachment element. One face of the disc supports a cushioning
layer between the traction element assembly and the disc.
Mechanical attachment of the traction elements to the shoe
attachment portion of the cleat allows a wider range of materials
to be used for cleat components than are possible with a bonded
coupling.
[0053] The traction element assembly may be coupled to the shoe
attachment portion in one of several ways. First, the traction
element assembly may be fabricated as a structure separate from the
shoe attachment portion. The assembly may then couple mechanically
to the shoe attachment portion with a fastener. The assembly may
include an integral fastener which attaches to the cleat or a
separate fastener, such as a rivet, may couple the traction element
assembly to the cleat. Second, traction elements forming the
assembly may be fabricated as part of the shoe attachment portion
disc, typically on the disc's perimeter. These elements can then
fold over towards the center of the disc. For example, the traction
elements can attach to the face of the disc with a fastener, such
as a rivet, or a portion of the traction element can serve as a
coupling element (male or female) mating to the complementary
element on the face of the disc.
[0054] An illustrative embodiment of this aspect of the invention
is shown in FIGS. 13 to 15. FIG. 13 is an exploded view of a cleat
1300. The traction element assembly 1310 couples a cushioning layer
1320 to the shoe attachment portion 1330 of the cleat. The traction
element assembly 1310 includes an integral snap-fit coupler 1315.
To assemble the cleat, the cushioning layer 1320 is placed on the
shoe attachment portion 1330 or bonded to it. The snap-fit coupler
of the traction element assembly 1310 may then be inserted through
the hole in the cushioning layer and into the hole in the center of
the shoe attachment portion of the cleat. Thus, a sandwich of the
three structures is formed. In other embodiments of the invention,
a variety of coupler element types may be used, as are known in the
art. FIG. 14 shows a perspective view of the assembled cleat 1300
and FIG. 15 shows a cross-sectional view of the cleat. In a
specific embodiment of the invention, the integral coupler can be
replaced with a separate rivet that fits through the traction
element assembly and attaches the traction element assembly 1310 to
the disc 1330.
[0055] In another illustrative embodiment of the invention, as
shown in FIG. 16, a separate fastener (in this case, a rivet)
connects one end of each traction element to the shoe attachment
portion of a cleat 1600. The cleat includes a disc 1610 with
opposing faces, a traction element array 1620, one or more
fold-over traction elements 1630, and a rivet 1640. The traction
element array 1620 engages the ground-facing face of the disc 1610.
The array 1620 may be bonded to this face of the disc. As shown in
FIG. 17, each traction element 1630 is attached on one end to the
perimeter of the disc 1610, with the other end of the traction
element free to move. Each traction element 1630 can be folded over
towards the center of the disc 1610. A rivet 1640 can then be
inserted into the center of the disc 1610. This rivet attaches the
free end of each traction element 1630 to the face of the disc.
FIG. 17 illustrates the operation of folding over the traction
element 1630 and attaching the element to the face of the disc 1610
with a rivet 1640. The flex of the traction elements 1630 when it
is folded over to the center of the disc advantageously enhances
the wearer's comfort as the cleat impacts the ground surface. In
some embodiments of the invention, cushioning material may be
bonded to the disc face over which the traction elements fold,
providing additional resiliency to the flex of the folded-over
traction element.
[0056] In another embodiment of this aspect of the invention, as
shown in FIG. 18, each traction element 1800 includes a coupling
element 1810 on the traction element's free end. The traction
element 1800 is folded over and the coupling element 1810 is
inserted into a corresponding coupling element 1840 in the
ground-facing face of the disc 1830. The traction element 1800
forms a cavity 1850 when the element is folded over and coupled to
the ground-facing face of the disc. Cushioning material may be
placed on the face of the disc so that this material fits into the
cavity 1850 formed by the folded-over traction element 1800. When
pressure from the outsole of the shoe forces the traction surface
1820 of the traction element 1800 into the turf as the wearer
steps, the flex of the traction element and the resiliency of the
cushioning layer advantageously enhance the wearer's comfort. While
a male coupling element 1810 is shown at the end of the traction
element 1800, in specific embodiments of the invention, the
traction element may include a female coupling element at its free
end with a corresponding male coupling element embedded in the
disc.
[0057] In specific embodiments of the invention, any of the above
cleat embodiments may include one or more of the following
variations:
[0058] The shoe attachment element structure may employ any
structure known in the art, such as a threaded stud, a Q-LOK.TM.
structure, a TRI-LOK.TM. structure, etc.
[0059] The durometer of the traction elements may range from about
Shore 60A to about Shore 98A.
[0060] The cushioning layer material may range in durometer from
about Shore 10A to about Shore 50A and may comprise plastic or
rubber or another compressible material.
[0061] The cushioning layer material and the traction element or
traction element assembly material can be matched so that the
difference in durometer between the cushioning layer and the
traction element assembly ranges from about 20 to about 70 points
on the Shore durometer scale.
[0062] The cleat materials may be tailored for factors such as the
characteristics of the shoe wearer or the characteristics of the
ground surface. For example, a heavier player may be provided with
a cleat with a cushioning layer material that is (relatively)
harder, coupled with a correspondingly harder traction element
material. A smaller or lighter weight player may be provided a
cleat with corresponding softer elements. As a second example, for
play on dry, hard, firm ground a cleat with a larger spread between
the hardness of the cushioning layer and the traction element
assembly may be provided. For play on wet or soft ground, a cleat
with a smaller spread between the hardness of the elements may be
advantageously employed.
[0063] Cleat Fabrication
[0064] The cleats described above may be fabricated using
conventional techniques, as are known in the art, such as injection
molding. In one preferred method of fabricating a cleat, a two-step
process is employed. First, one element, either the traction
element or the shoe attachment portion of the cleat, is molded.
Then, this first element is used as an "insert" in a two-color and
two-injection plastic molding machine. This second operation molds
two elements, in two different colors, and bonds the three elements
together. In practice, the single "insert element" may be loaded
into the second machine either by hand, or automatically by a "pick
and place" robotic arm. In a second preferred method, the traction
element and the attachment element are made separately in injection
plastic molding machines, as individual pieces. Then, these
separate pieces are loaded as inserts into a second machine. In the
second machine, the third material is injected into the middle,
bonding the cleat together.
[0065] Similarly, it is of course apparent that the present
invention is not limited to the detailed description set forth
above. Various changes and modifications of this invention as
described will be apparent to those skilled in the art without
departing from the spirit and scope of this invention as defined in
the appended clauses.
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