U.S. patent application number 13/759893 was filed with the patent office on 2014-08-07 for cleats, cleated sole structures, molds, and molding methods for in-molding articles.
This patent application is currently assigned to NIKE, INC.. The applicant listed for this patent is NIKE, INC.. Invention is credited to Darien Curl, Dick Lin, Nicole Mueller, Ricardo Salinas, JR., David Tu.
Application Number | 20140215857 13/759893 |
Document ID | / |
Family ID | 51258011 |
Filed Date | 2014-08-07 |
United States Patent
Application |
20140215857 |
Kind Code |
A1 |
Curl; Darien ; et
al. |
August 7, 2014 |
CLEATS, CLEATED SOLE STRUCTURES, MOLDS, AND MOLDING METHODS FOR
IN-MOLDING ARTICLES
Abstract
Cleat structures, e.g., for golf shoes, may include a flat and
flexible interior surface and/or a generally disk-shaped perimeter
area that includes features to promote in-molding of the cleat to a
footwear sole component (e.g., to permanently engage the cleat with
an outsole member). Such cleats may provide a flexible and
comfortable base, including a low profile, e.g., to enable
formation relatively thin and/or flexible footwear sole components.
Footwear sole components and articles of footwear that include one
or more in-molded cleat structures of this type also are described.
Molds used for in-molding procedures and methods of using the molds
to make articles with in-molded components (e.g., for making
footwear sole structures including one or more in-molded cleats)
also are described.
Inventors: |
Curl; Darien; (Beaverton,
OR) ; Lin; Dick; (Beaverton, OR) ; Mueller;
Nicole; (Portland, OR) ; Salinas, JR.; Ricardo;
(Hillsboro, OR) ; Tu; David; (Beaverton,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, INC. |
Beaverton |
OR |
US |
|
|
Assignee: |
NIKE, INC.
Beaverton
OR
|
Family ID: |
51258011 |
Appl. No.: |
13/759893 |
Filed: |
February 5, 2013 |
Current U.S.
Class: |
36/134 ;
36/25R |
Current CPC
Class: |
A43C 15/16 20130101;
B29D 35/148 20130101; A43B 13/122 20130101; B29D 35/142 20130101;
A43C 15/162 20130101; A43C 15/161 20130101; A43B 13/26 20130101;
A43B 5/001 20130101; B29D 35/128 20130101 |
Class at
Publication: |
36/134 ;
36/25.R |
International
Class: |
A43C 15/16 20060101
A43C015/16 |
Claims
1. A sole element for an article of footwear, comprising: a cleat
including an interior surface, an exterior surface opposite the
interior surface, and an outer flange, wherein the outer flange
includes a first surface, a second surface opposite the first
surface, and an outer perimeter edge extending between the first
and second surfaces, wherein a plurality of perimeter openings
extending through the outer flange are located adjacent the outer
perimeter edge; and a sole component engaged with the cleat,
wherein the sole component includes a continuous layer of material
that covers the outer perimeter edge, extends over the first and
second surfaces of the outer flange, and through the plurality of
perimeter openings.
2. A sole element according to claim 1, wherein at least 95% of a
bottom surface of the sole component is planar, substantially
planar, or smoothly curved.
3. A sole element according to claim 1, wherein the sole component
completely covers the interior surface of the cleat.
4. A sole element according to claim 1, wherein the sole component
constitutes an outsole component.
5. A sole element according to claim 1, wherein the sole component
includes an exterior base area and a plurality of traction elements
integrally formed with the sole component and extending outward
from the exterior base area.
6. A sole element according to claim 5, wherein the exterior base
area of the sole component exclusive of a thickness of the traction
elements has a maximum thickness of 7 mm or less.
7. A sole element according to claim 5, wherein the sole element
has a maximum thickness through the cleat and the sole component of
15 mm or less.
8. A sole element according to claim 1, wherein the continuous
layer of material completely covers the plurality of perimeter
openings.
9. A sole element according to claim 1, wherein at least 95% of the
interior surface of the cleat is planar, substantially planar, or
smoothly curved.
10. A sole element according to claim 1, further comprising: a
second cleat including a second interior surface, a second exterior
surface opposite the second interior surface, and a second outer
flange, wherein the second outer flange includes a third surface, a
fourth surface opposite the third surface, and a second outer
perimeter edge extending between the third and fourth surfaces,
wherein a second plurality of perimeter openings extending through
the second outer flange are located adjacent the second outer
perimeter edge, and wherein the continuous layer of material of the
sole component additionally covers the second outer perimeter edge,
extends over the third and fourth surfaces of the second outer
flange, and extends through the second plurality of perimeter
openings.
11. A sole element according to claim 10, wherein at least 95% of a
bottom surface of the sole component is planar, substantially
planar, or smoothly curved.
12. A sole element according to claim 10, wherein the sole
component completely covers the interior surface of the cleat.
13. A sole element according to claim 10, wherein the sole
component constitutes an outsole component.
14. A sole element according to claim 10, wherein the sole
component includes an exterior base area and a plurality of
traction elements integrally formed with the sole component and
extending outward from the exterior base area.
15. A sole element according to claim 14, wherein the exterior base
area of the sole component exclusive of a thickness of the traction
elements has a maximum thickness of 7 mm or less.
16. A sole element according to claim 10, wherein the continuous
layer of material completely covers the plurality of perimeter
openings and the second plurality of perimeter openings.
17. A sole element according to claim 10, wherein at least 95% of
the interior surface of the cleat is planar, substantially planar,
or smoothly curved, and wherein at least 95% of the second interior
surface of the second cleat is planar, substantially planar, or
smoothly curved.
18. A sole element according to claim 1, further comprising: a
second cleat including a second interior surface, a second exterior
surface opposite the second interior surface, and a second outer
flange, wherein the second outer flange includes a third surface, a
fourth surface opposite the third surface, and a second outer
perimeter edge extending between the third and fourth surfaces,
wherein a second plurality of perimeter openings extending through
the second outer flange are located adjacent the second outer
perimeter edge; and a third cleat including a third interior
surface, a third exterior surface opposite the third interior
surface, and a third outer flange, wherein the third outer flange
includes a fifth surface, a sixth surface opposite the fifth
surface, and a third outer perimeter edge extending between the
fifth and sixth surfaces, wherein a third plurality of perimeter
openings extending through the third outer flange are located
adjacent the third outer perimeter edge, and wherein the continuous
layer of material of the sole component additionally covers the
second and third outer perimeter edges, extends over the third,
fourth, fifth, and sixth surfaces, and extends through the second
and third plurality of perimeter openings.
19. An article of footwear, comprising: an upper; and a sole
structure engaged with the upper, wherein the sole structure
includes a sole element having: a cleat including an interior
surface, an exterior surface opposite the interior surface, and an
outer flange, wherein the outer flange includes a first surface, a
second surface opposite the first surface, and an outer perimeter
edge extending between the first and second surfaces, wherein a
plurality of perimeter openings extending through the outer flange
are located adjacent the outer perimeter edge; and a sole component
engaged with the cleat, wherein the sole component includes a
continuous layer of material that covers the outer perimeter edge,
extends over the first and second surfaces of the outer flange, and
through the plurality of perimeter openings.
20. An article of footwear according to claim 19, wherein the
article of footwear is a golf shoe.
21. An article of footwear according to claim 19, wherein the sole
structure includes a midsole component engaged with the upper, and
wherein the sole element is engaged with the midsole component.
22. An article of footwear according to claim 19, wherein the sole
structure further includes a second sole element having: a second
cleat including a second interior surface, a second exterior
surface opposite the second interior surface, and a second outer
flange, wherein the second outer flange includes: (a) a third
surface, (b) a fourth surface opposite the third surface, and (c) a
second outer perimeter edge extending between the third and fourth
surfaces, wherein a second plurality of perimeter openings
extending through the second outer flange are located adjacent the
second outer perimeter edge; and a second sole component engaged
with the second cleat, wherein the second sole component includes a
continuous layer of material that covers the second outer perimeter
edge, extends over the third and fourth surfaces of the second
outer flange, and through the second plurality of perimeter
openings.
23. An article of footwear according to claim 22, wherein the
article of footwear is a golf shoe.
24. An article of footwear according to claim 22, wherein the sole
structure includes a midsole component engaged with the upper, and
wherein the first sole element is engaged with the midsole
component and the second sole element is engaged with the midsole
component.
25. An article of footwear according to claim 24, wherein the first
sole element is located in a forefoot area of the midsole component
and the second sole element is located in a heel area of the
midsole component.
Description
FIELD OF THE INVENTION
[0001] The present invention in part relates to the field of
footwear. More specifically, some aspects of the present invention
pertain to cleat structures, sole structures including such cleat
structures, and articles of footwear (e.g., athletic footwear) that
include such sole structures. Additional aspects of this invention
relate to molds and methods of molding articles that may be used,
for example, to produce articles with in-molded structures,
including footwear sole structures with in-molded cleats.
BACKGROUND
[0002] Conventional golf shoes and other articles of footwear often
include cleat structures or other traction enhancing elements to
improve traction and provide a stable base for activities performed
by the wearer. Many cleats of this type include a threaded
connector or a turnbuckle type engagement structure to allow the
cleat to be releasably engaged with a footwear sole structure.
While useful to releasably engage the cleat with the shoe, such
connector structures have certain disadvantages. For example, the
treaded connector or turnbuckle type engagement structures
typically extend toward the bottom (plantar) surface of the
wearer's foot. Therefore, when the wearer stands and walks on the
shoe, distinct high pressure points often can be felt underfoot,
which lead to discomfort and/or fatigue, particularly after walking
in the shoes for 18 or more holes of golf (often over terrain of
varying slope and hardness).
[0003] Cushioning elements, rigid plates, or other pressure
moderator or force dispersing structures may be incorporated into
the footwear construction in an effort to reduce the point loading
and/or pressure forces experienced by the wearer. Such structures,
however, tend to increase the height of the shoe and/or reduce the
flexibility and/or natural motion feel of the shoe. Many golfers
find these features to be disadvantageous.
[0004] Additionally, the releasable connection between cleats and
the sole structure may cause the cleat elements to loosen and
become disengaged from the shoe, often without the wearer
immediately knowing. Such unintended loss of cleats can adversely
impact traction and potentially damage golf course mowing or
maintenance equipment.
[0005] Accordingly, there is room in the art for improvements in
cleated footwear structures, e.g., for golf shoes and/or other
cleated footwear constructions.
SUMMARY OF THE INVENTION
[0006] This Summary is provided to introduce some general concepts
relating to this invention in a simplified form that are further
described below in the Detailed Description. This Summary is not
intended to identify key features or essential features of the
invention.
[0007] Some aspects of this invention relate to cleat structures,
e.g., cleats for golf shoes or other cleated footwear. The cleat
structures may include a flat interior surface and/or a generally
disk-shaped perimeter area that includes structures to promote
in-molding of the cleat to a footwear sole component. Such cleats
may provide a flexible and comfortable base, e.g., to enable
formation relatively thin and/or flexible footwear sole
components.
[0008] Additional aspects of this invention relate to footwear sole
components (e.g., outsole components) and/or articles of footwear
that include one or more in-molded cleat structures, e.g., of the
types described above. Still additional aspects of this invention
relate to molds used for in-molding procedures and methods of using
the molds to make articles with in-molded components (e.g., for
making footwear sole structures including one or more in-molded
cleats).
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing Summary of the Invention, as well as the
following Detailed Description of the Invention, will be better
understood when considered in conjunction with the accompanying
drawings in which like reference numerals refer to the same or
similar elements in all of the various views in which that
reference number appears.
[0010] FIGS. 1A through 1D illustrate various views of cleat
structures, sole structures, and articles of footwear according to
examples of this invention;
[0011] FIGS. 2A through 2E illustrate various views of cleat
structures according to examples of this invention;
[0012] FIGS. 3A through 3H provide various views illustrating
features of mold structures, methods of molding, and molded
products according to examples of this invention; and
[0013] FIGS. 4A through 4D provide views comparing a known cleat
and sole construction (FIGS. 4A and 4B) with a cleat and sole
construction in accordance with one example of this invention
(FIGS. 4C and 4D).
DETAILED DESCRIPTION OF THE INVENTION
[0014] In the following description of various examples of
structures, components, and methods according to the present
invention, reference is made to the accompanying drawings, which
form a part hereof, and in which are shown by way of illustration
various example structures, environments, and methods in which
aspects of the invention may be practiced. It is to be understood
that other structures, environments, and methods may be utilized
and that structural and functional modifications may be made to the
specifically described structures and methods without departing
from the scope of the present invention.
[0015] I. General Description of Aspects of this Invention
[0016] As noted above, aspects of this invention relate to cleat
structures, sole structures including cleat structures, and
articles of footwear (e.g., athletic footwear) that include such
sole structures. Additional aspects of this invention relate to
molds and methods of molding articles that may be used, for
example, to produce articles having in-molded structures or
components, including footwear sole structures having in-molded
cleats.
[0017] A. Cleat Constructions According to Aspects of this
Invention
[0018] Some aspects of this invention relate to cleat constructions
that can be incorporated into articles of footwear, such as
athletic footwear (and in some specific examples, golf footwear).
In some more specific examples, the cleats may be fixed or
permanently incorporated into the sole structure of the article of
footwear.
[0019] As a more specific example, cleats in accordance with at
least some examples of this invention may include: (A) a cleat
component made from a first material, wherein the cleat component
includes: (i) a first leg having a first anchor post extending from
a bottom side of the first leg toward a bottom surface of the cleat
component, (ii) a second leg having a second anchor post extending
from a bottom side of the second leg toward the bottom surface of
the cleat component, and (iii) a third leg having a third anchor
post extending from a bottom side of the third leg toward the
bottom surface of the cleat component; and (B) a cleat base engaged
with the cleat component at the first, second, and third anchor
posts, wherein the cleat base is made from a second material that
is different from the first material. Two legs or more than three
legs may be provided in some cleat structures without departing
from this invention.
[0020] Another example of cleats in accordance with at least some
aspects of this invention includes: (A) a cleat component made from
a first material, wherein the cleat component includes: (i) a first
leg, (ii) a second leg, (iii) a third leg, (iv) a first ridge
extending between the first and second legs, (v) a second ridge
extending between the second and third legs, and (vi) a third ridge
extending between the first and third legs; and (B) a cleat base
engaged with the cleat component such that a first portion of the
cleat base at least partially surrounds the first ridge, a second
portion of the cleat base at least partially surrounds the second
ridge, and a third portion of the cleat base at least partially
surrounds the third ridge, wherein the cleat base is made from a
second material that is different from the first material. Other
numbers of legs and/or intermediate ridges also may be used (e.g.,
2-6 legs and/or intermediate ridges) without departing from this
aspect of the invention.
[0021] Yet another example of cleats in accordance with at least
some aspects of this invention include: (A) a cleat base including
a first surface, a second surface opposite the first surface, and
an outer perimeter, wherein the cleat base is made from a first
material, and wherein the cleat base includes: (i) a set of
perimeter openings extending from the first surface to the second
surface and located adjacent the outer perimeter and (ii) a first
inner opening at least partially located inside the set of
perimeter openings; and (B) a cleat component extending through
and/or engaged with the cleat base at the first inner opening,
wherein the cleat component is made from a second material that is
different from the first material, and wherein the cleat component
includes: (i) a first (exterior) surface that includes one or more
traction enhancing structures and (ii) a second (interior) surface
opposite the first surface. In this example cleat structure, a
bottom of the cleat is located inside the outer perimeter of the
cleat base, wherein at least 95% of an area of the bottom of the
cleat comprises the second surface of the cleat base, the second
surface of the cleat component, and the set of perimeter openings,
and wherein at least 95% of a combined surface area of the second
surfaces of the cleat base and the cleat component is planar,
substantially planar, or smoothly curved.
[0022] In the example cleat structures described above, if desired,
the cleat base may be permanently engaged with the article of
footwear, e.g., in-molded or otherwise permanently fixed to the
sole structure of the shoe (although it may be releasably attached
to the article of footwear, if desired). Additionally or
alternatively, if desired, the cleat component may be releasably
engaged with the cleat base so that the cleat component may be
replaced on the cleat base, if desired. In some specific example
structures in accordance with this invention, however, the cleat
base will be in-molded or otherwise permanently fixed to the sole
structure of the shoe (e.g., by cements or adhesives, by mechanical
connectors, etc.) and the cleat component will be in-molded or
otherwise permanently fixed to the cleat base (e.g., by cements or
adhesives, by mechanical connectors, etc.), such that the entire
cleat is permanently fixed with the article of footwear (e.g.,
fixed in a non-replaceable manner).
[0023] In cleat structures in accordance with at least some
examples of this invention, the cleat component may include a
central opening, and a portion of the cleat base may extend to
and/or be exposed to an outer (exterior) surface of the cleat
through this central opening. If desired, the portion of the cleat
base exposed at the outer surface of the cleat through the central
opening may be surrounded by the cleat component. If desired, in
the final cleat structure, the material from which the cleat base
is formed (e.g., a nylon material) may be harder than the material
from which the cleat component is formed (e.g., a thermoplastic
polyurethane material). The cleat base may be at least somewhat
flexible, and it may be constructed so as to be free from threaded
connectors, turnbuckle type connectors, and/or other structures for
releasably engaging the cleat with an article of footwear. If the
cleat base is flexible, this may help allow the cleat to feel more
comfortable underfoot (e.g., to better conform with the foot
shape). This flexibility likewise may enable the cleat base to flex
as force is placed on the overall sole component, which may help
the cleat to bend with the rubber or other material of the sole
component rather than remaining stiff and unbent and pulling away
from the material of the sole component.
[0024] The outer perimeter of the cleat base may surround a single
cleat in at least some examples of this invention. If desired, at
least 90% of an area of a bottom of the cleat located inside the
outer perimeter of the cleat base may constitute a bottom surface
of the cleat component and a bottom surface of the cleat base, and
at least 95% of a combined surface area of the bottom surfaces of
the cleat component and the cleat base may be planar, substantially
planar, or smoothly curved. In some structures, at least 98% of
this combined surface area may be planar, substantially planar, or
smoothly curved.
[0025] In cleat structures in accordance with at least some
examples of this invention, an exterior surface of the cleat base
(i.e., the surface exposed to and in contact with the ground in
use) may include one or more traction enhancing structures, such as
fin cleats, nubs, pyramids, truncated pyramids, cylinders, and the
like. These additional fraction enhancing structures may be located
between adjacent legs of the cleat component.
[0026] Cleat components in accordance with at least some examples
of this invention may include ridges that extend between adjacent
legs of the cleat components. The overall cleat then may be formed
so that portions of the cleat base surround the ridges and/or
extend through openings provided in the ridges to thereby engage
the cleat bases with the cleat components. In such structures, the
cleat may be formed by first forming the cleat components (e.g., by
an injection molding process) and then forming the cleat base
around the cleat component, e.g., in an in-molding process.
[0027] Additionally, if desired, cleat structures in accordance
with at least some examples of this invention may include the
various features described above in any desired combinations or sub
combinations.
[0028] Still additional aspects of this invention relate to sole
structures for articles of footwear (e.g., including midsole and/or
outsole components) that have cleat structures of the types
described above, as well as to articles of footwear (e.g., golf
shoes) incorporating cleat structures and/or sole structures of the
types described above.
[0029] B. Sole Structures According to Aspects of this
Invention
[0030] Additional aspects of this invention relate to sole elements
for articles of footwear. Such sole elements, which may constitute
outsoles, midsoles, or midsole/outsole combinations, may include:
(A) a cleat including an interior surface, an exterior surface
opposite the interior surface, and an outer flange or rim, wherein
the outer flange or rim includes a first surface, a second surface
opposite the first surface, and an outer perimeter edge extending
between the first and second surfaces, and wherein a plurality of
perimeter openings extending through the outer flange or rim are
located adjacent (and inside) the outer perimeter edge; and (B) a
sole component engaged with the cleat, wherein the sole component
includes a continuous layer of material that at least partially
covers the outer perimeter edge, extends over at least some of the
first and second surfaces of the outer flange or rim, and extends
through at least some of the plurality of perimeter openings. If
desired, the sole component may completely cover the interior
surface of the cleat, and the material of the sole component may
completely fill the plurality of perimeter openings. The cleat may
include the structures described above and/or any combination or
subcombination of the cleat features and/or structures described
above. Also, while it may be removable from the sole component, in
some more specific structures in accordance with examples of this
invention, the cleat (or at least the cleat base) will be
permanently fixed to the sole component (e.g., by an in-molding
process, by cements or adhesives, by mechanical connectors,
etc.).
[0031] If desired, an exterior surface of the sole component (i.e.,
the surface exposed to and in contact with the ground in use) may
include one or more traction enhancing structures, such as fin
cleats, nubs, pyramids, truncated pyramids, cylinders, removable
cleats, and the like. The base area of the sole component,
exclusive of a thickness of any traction elements formed therein,
may have a maximum thickness of 7 mm or less, and in some examples,
6 mm or less, or even 5 mm or less. If desired, some sole elements
in accordance with examples of this invention will have an overall
maximum thickness through the cleat and the sole component (e.g.,
cleat plus outsole plus midsole thickness or height) of 15 mm or
less, and in some examples, 13 mm or less, 10 mm or less, or even 7
mm or less.
[0032] Any desired number of cleats, e.g., of the types described
above, may be engaged with a single sole component without
departing from this invention. The cleats provided on a given sole
component may have the same or different constructions and/or may
be engaged with the sole component in the same or different
manners.
[0033] Still additional aspects of this invention relate to sole
structures for articles of footwear including one or more sole
elements of the types described above (e.g., including midsole
and/or outsole components), as well as to articles of footwear
(e.g., golf shoes) incorporating cleat structures and/or sole
elements of the types described above. If desired, the overall sole
structure may include an outsole component (e.g., formed of a
rubber or TPU material) with the cleat incorporated into it (e.g.,
by in-molding), and this outsole component may be engaged with a
midsole component (e.g., including a polymeric foam material, one
or more fluid-filled bladders, and/or one or more mechanical impact
force attenuating components). The combined midsole/outsole
structure then may be engaged with one or more upper and/or other
footwear components (e.g., by sewing or stitching, by adhesives or
cements, and/or by mechanical connectors, etc.).
[0034] C. Mold Structures According to Aspects of this
Invention
[0035] Additional aspects of this invention relate to mold
structures, e.g., for making molded products including in-molded
components (e.g., for making a sole element for an article of
footwear including an in-molded cleat). Some mold structures in
accordance with aspects of this invention will include: (a) a first
mold component (e.g., a first mold plate) including a first portion
of a mold cavity and (b) a second mold component (e.g., a second
mold plate) including a second portion of the mold cavity for at
least partially covering the first portion of the mold cavity. The
first portion of the mold cavity may include: (i) a first area for
forming and/or shaping a first portion of an article to be molded
(e.g., a footwear sole structure, such as an outsole component),
wherein the first area includes a first molding surface exposed in
the mold cavity made from a first material having a first thermal
conductivity, and (ii) one or more additional areas (e.g., also
called "second" and "third areas herein) including a component
receptacle for receiving a component to be in-molded into the
article (e.g., for receiving a previously formed cleat element),
wherein the component receptacle includes a second surface exposed
in the mold cavity for engaging the component to be in-molded, and
wherein the second surface is made from a second material having a
second thermal conductivity that is less than the first thermal
conductivity. If desired, a separate "second area" and/or component
receptacle may be provided for each individual component (e.g.,
each individual cleat element) to be in-molded into the article.
The individual "second areas" and/or component receptacles (when
multiple areas and/or receptacles are present) may be completely
separated from one another (e.g., such that the first molding
surface forms a continuous path between the individual component
receptacles and/or such that the first area of the mold cavity
completely surrounds the individual component receptacle areas).
The second mold component may completely cover the first portion of
the mold cavity and/or completely cover one or more of the
component receptacles.
[0036] As noted above, the first molding surface exposed in the
mold cavity (for forming the first portion of an article to be
molded (e.g., a footwear sole structure, such as an outsole
component)) is made from a first material having a first thermal
conductivity and the second surface exposed in the mold cavity (for
engaging the component to be in-molded) is made from a second
material having a second thermal conductivity that is less than the
first thermal conductivity. As some more specific examples, the
first material may include a metal or metal alloy material (e.g.,
aluminum, steel, etc.) and the second material may include at least
one material selected from the group consisting of: a ceramic
material, a polymeric material, and a polymeric material including
a ceramic, metal, or metal alloy powder dispersed therein. By
having a lower thermal conductivity, the material of the second
surface (e.g., the in-molded component receptacle surface) will
heat up less quickly than the material of the first molding
surface. This enables in-molding of a component that may not be
satisfactorily in-molded at the temperatures, pressures, and/or
timing conditions necessary for molding the article to be molded
(i.e., components that might normally melt and/or otherwise deform
under the necessary molding conditions).
[0037] As a more specific example, a previously formed cleat
component may be engaged within a mold cavity at a cleat receptacle
made from the second material described above. Because the surface
of the cleat receptacle has a lower thermal conductivity than the
material of the surrounding area (against which the outsole
component is shaped and/or formed), the cleat receptacle does not
heat up as quickly as the surrounding molding surface. Because the
cleat receptacle heats up more slowly than the remainder of the
molding surface, the cleat component may be placed in the mold
cavity and engaged with an outsole component by an in-molding
process under timing, temperature, and/or pressure conditions that
could cause the cleat component to melt or deform if it was engaged
directly with the material against which the outsole component is
formed. In effect, in this example, the material of the cleat
receptacle maintains the area of the mold in contact with the cleat
component at a lower temperature during the outsole rubber molding
cycle to prevent the cleat component from melting or otherwise
deforming during the outsole rubber molding process.
[0038] Molds of the types described above may be used to form
outsole components including in-molded cleats of any desired
construction, including outsole components and/or in-molded cleats
of the various types described above (and described in more detail
below).
[0039] D. Molding Methods According to Aspects of this
Invention
[0040] Still additional aspects of this invention relate to methods
of forming molded articles (e.g., footwear sole structures), e.g.,
using the mold structures described above. Such methods may include
placing a component to be in-molded (e.g., a cleat component) in a
mold cavity, wherein the component to be in-molded includes an
in-molding engagement area (e.g., a perimeter area, such as a
flange or rim), and wherein the mold cavity includes: (i) a first
area that includes a first molding surface exposed in the mold
cavity made from a first material having a first thermal
conductivity, and (ii) one or more additional areas including one
or more in-molded component receptacles (e.g., a cleat receptacle),
wherein the in-molded component receptacle includes a second
surface exposed in the mold cavity for engaging the component to be
in-molded, wherein the second surface is made from a second
material having a second thermal conductivity that is less than the
first thermal conductivity, and wherein the component to be
in-molded is engaged with the in-molded component receptacle. The
method further may include introducing a moldable material into the
mold cavity, wherein the moldable material flows around and/or
through the in-molding engagement area of the component to be
in-molded to engage the component to be in-molded with the moldable
material. The mold may be held at temperature and/or pressure
conditions for a sufficient time to enable the moldable material to
flow to the desired areas to form the final article to be molded.
Additional features of methods according to this aspect of the
invention may include curing the moldable material after the step
of introducing the moldable material into the mold cavity (inside
or outside of the mold).
[0041] The moldable material may be introduced into the mold cavity
in one or more steps. In some more specific examples, a first
portion of the moldable material will be introduced into the mold
cavity before the component to be in-molded is engaged with the
component receptacle and then a second portion of the moldable
material will be introduced into the mold cavity after the
component to be in-molded is engaged with the component receptacle.
In such methods, it may be necessary or desirable to clear the
moldable material from the component receptacle area(s) before
engaging the component to be in-molded with the receptacle area(s).
Alternatively, if desired, the mold cavity may include an
intermediate plate or other structure that prevents the moldable
material from flowing over the component receptacle area(s) when
the component(s) to be in-molded is (are) absent from the mold
cavity.
[0042] When used to form outsole components with in-molded cleat
elements of the types described above, molding methods according to
aspects of this invention may further include engaging the outsole
component (e.g., including a combined base footwear sole component
and the in-molded cleat) with a midsole component, e.g., by cements
or adhesives, by mechanical connectors, etc. The midsole component
may have any desired structure without departing from this
invention, including, for example, midsole components including a
polymeric foam material, midsole components includes one or more
fluid-filled bladders (optionally with the fluid-filled bladder(s)
at least partially surrounded by a foam material), midsole
components including one or more mechanical impact force
attenuating structures, etc.
[0043] Sole structures of the types described above (including
those made by the methods described above) may be incorporated into
an article of footwear, e.g., to one or more upper components), in
any desired manner, including in manners that are conventionally
known and used in the footwear art.
[0044] Given the general description of features, aspects,
structures, processes, and arrangements according to certain
embodiments of the invention provided above, a more detailed
description of specific example structures and methods in
accordance with this invention follows.
[0045] II. Detailed Description of Example Structures and Methods
According to this Invention
[0046] Referring to the figures and following discussion, various
articles of footwear, footwear components, and features thereof in
accordance with the present invention are described. The footwear
depicted and discussed are golf shoes, but the concepts disclosed
with respect to various aspects of this invention may be applied to
a wide range of cleated or other athletic footwear styles,
including, but not limited to: football shoes, hiking shoes, soccer
shoes, baseball shoes, track shoes, and the like. Still additional
concepts and aspects of this invention, such as the mold
construction and molding method concepts and aspects of the
invention, may be applied to production of other products, such as
other products in which one or more permanently attached, in-molded
components may be desired. Accordingly, the present invention is
not limited to the precise embodiments disclosed herein, but it
applies more generally to other types of footwear and/or other
product lines.
[0047] FIGS. 1A and 1B show medial and lateral side views,
respectively, of a golf shoe 100 in accordance with some aspects of
this invention. FIG. 1C provides a bottom view of this example golf
shoe 100, and FIG. 1D provides an enlarged close-up view of one
cleat element 150 provided on this example golf shoe 100. The shoe
100 includes an upper 102 and a sole structure 104 engaged with the
upper 102. The upper 102 may be made from any desired material or
combination of materials without departing from this invention,
including from material(s) and/or construction(s) as are generally
known and used in the footwear art. Some more specific examples of
upper 102 materials include fabric or textiles, leathers (synthetic
or natural), polymeric materials, spacer meshes, and the like. The
upper 102, at least in part, defines a foot-receiving opening 106
through which the wearer inserts a foot to don the shoe 100. Laces
108 or other securing or foot engagement structures may be provided
to securely hold the shoe 100 to a wearer's foot. In this
illustrated example, the lace 108 engages a strap element 110 that
wraps around the shoe 100 (including around and across the bottom
of the sole structure 104) to help conform the shoe to the wearer's
foot as the lace 108 is tightened. Also, if desired, the strap
element 110 can be removable (e.g., by unlacing the lace 108) and
replaced by another strap element 110, e.g., to change colors,
styles, and/or shapes of the strap element 110, to otherwise change
the appearance and/or feel of the strap element 110, etc. A tongue
member 112, bootie, or other similar type structure may be provided
at the shoe instep area, e.g., to increase comfort and/or to
moderate the pressure and feel applied to the wearer's foot by the
lace 108.
[0048] The sole structure 104 may be engaged with the upper 102 in
any desired manner, including in manners that are conventionally
known and used in the footwear art (e.g., by sewing or stitching,
by adhesives or cements, by mechanical connectors, etc.). In this
illustrated example, the sole structure 104 includes a midsole
component 104a and an outsole component 104b engaged with the
midsole component 104a. This engagement may be accomplished in any
desired manner, including manners that are conventionally known or
used in the footwear art (e.g., by cements or adhesives, by
mechanical connectors, by sewing or stitching, etc.). In this
illustrated example, the outsole component 104b is formed by a
molding process (which will be described in more detail below)
separate from the midsole component 104a, and the outsole component
104b is formed in a shape to fit into shallow recesses formed in
the surface of the midsole component 104a. The two parts 104a, 104b
are fixed to one another by cement in this example.
[0049] The midsole component 104a may be made from any desired
materials and/or in any desired manner without departing from this
invention, including from conventional materials and in
conventional manners as are known and used in the art. As some more
specific examples, the midsole component 104a may be formed from
and/or include one or more of: a polymeric foam material (e.g., a
polyurethane foam, an ethylvinylacetate foam, etc.); one or more
fluid-filled bladders (e.g., optionally at least partially
incorporated into a foam material and/or a plastic cage type
structure); one or more polymeric foam columns (e.g., like the
columns provided in NIKE SHOX.TM. type footwear); one or more
mechanical impact force attenuating components; etc. In some
examples, the midsole component 104a may be at least partially made
from a foam material having a density of less than 0.25 g/cm.sup.3
(and in some examples, a density of less than 0.2 g/cm.sup.3,
within the range of 0.075 to 0.2 g/cm.sup.3, and even within the
range of 0.1 to 0.18 g/cm.sup.3); a foam material as described, for
example, in U.S. Pat. No. 7,941,938 (which patent is entirely
incorporated herein by reference); and/or a foam material from the
"LUNAR" family of footwear products available from NIKE, Inc. of
Beaverton, Oreg. The midsole component 104a also may be formed from
any desired number of independent pieces or parts without departing
from this invention.
[0050] The outsole component 104b of this example shoe structure
100 also may be made from any desired materials without departing
from this invention, including from conventional materials as are
known and used in the art. In accordance with at least some aspects
of this invention, the outsole component 104b may be made from a
synthetic rubber material (e.g., a conventional outsole rubber
material). The sole structure 104 of this example footwear
structure 100 includes two separate outsole components 104b engaged
with a single polymeric foam midsole component 104a by cement or
adhesive. Outsole components 104b and production systems and
methods therefor in accordance with some aspects of this invention
will be described in more detail below.
[0051] As shown in FIGS. 1A through 1D, each separate outsole
component 104b of this example footwear structure 100 includes a
plurality of cleat elements 150 (or other fraction enhancing
components) engaged with it. While an individual outsole component
104b may have any desired number of separate cleat elements 150
engaged with it (including zero), in this illustrated example, the
forefoot outsole component 104b has three cleat elements engaged
with it (one on the medial side (inside) edge of the shoe 100 and
two on the lateral side (outside) edge, with the center of the
medial cleat 150 located between the centers of the two lateral
cleats 150 in the front-to-back direction). Similarly, the heel
outsole component 104b has two cleat elements 150 engaged with it
(one on the rear lateral side and one on the medial side and
forward of the other). Other cleat numbers, arrangements, and
orientations are possible without departing from this
invention.
[0052] FIGS. 1A through 1D further illustrate that the outsole
components 104b of this example structure 100 include a plurality
of secondary traction elements 152 integrally formed on the
exterior (bottom) surface of the outsole component 104b. While a
plurality of raised nubs (e.g., cylinders or truncated pyramids)
are shown in the figures, other traction element structures are
possible without departing from this invention, such as raised fin
type cleat structures, raised ribs, recessed grooves, etc. While
provided primarily on the bottommost contact surface of the outsole
component 104b, if desired, at least some of these secondary
traction elements 152 may be provided along a side area of the sole
structure 104 (e.g., as shown in FIGS. 1A and 1B). These side
oriented secondary traction elements 152 can be particularly
useful, for example, as the user's weight shifts during the course
of a golf swing, during a cutting or rapid direction change
maneuver, etc.
[0053] More specific features and components of an example cleat
structure 150 in accordance with at least some examples of this
invention will be discussed below in conjunction with FIGS. 2A
through 2E. This example cleat structure 150 includes a cleat
component 154 (e.g., including traction enhancing element
structures) and a cleat base 156. The cleat component 154 may be
engaged with the cleat base 156 in any desired manner, including
through the use of cements or adhesives, via a friction fit, via
detents or spring loaded type connections, etc. FIGS. 2A and 2B
provide top and bottom views, respectively, of the cleat component
154, and FIGS. 2C-2E provide bottom, top, and cross sectional views
of the overall cleat structure 150.
[0054] The cleat component 154 and the cleat base 156 may be made
from any desired materials without departing from this invention.
In some specific example cleat constructions according to this
invention, the cleat component 154 will be formed from a
thermoplastic polyurethane material (TPU) and the cleat base 156
will be formed from a nylon 66 material. Other materials and/or
combinations of materials also may be used without departing from
this invention, including material combinations in which, in the
finished cleat product, the cleat component 154 is made from a
softer material than the cleat base 156, although the cleat base
156 may remain at least somewhat flexible (particularly at its
perimeter flange or rim area). As some more specific examples, the
finished cleat component 154 may be made from a TPU material having
a Shore A hardness ranging from 80 to 120 (and in some examples, in
a range from about 90-100 Shore A, or even about 92-96 Shore A). In
terms of Shore D hardness, the finished cleat component 154 of some
example structures may be made from a TPU material having a Shore D
hardness ranging from 36 to 52 Shore D (and in some examples, in a
range from about 40-48 Shore D or even from about 42-46 Shore D).
The finished cleat base 156 may be made from a nylon material
having a Shore D hardness of about 70 to 88 Shore D, and in some
examples, within the range of 75 to 85 Shore D or even 76 to 82
Shore D.
[0055] In some examples of this aspect of the invention, the cleat
structure 150 may be made from the two parts noted above by an
in-molding process. More specifically, first the cleat component
154, e.g., as shown in FIGS. 2A and 2B, may be produced as a single
part, for example, by an injection molding process. As shown in
FIGS. 2A and 2B, this example cleat component 154 (which may be
made from thermoplastic polyurethane material) may include a
plurality of legs 158 that form some of the traction-enhancing
elements of the cleat 150. The cleat component 154 constitutes a
single piece construction in which the legs 158 extend outward
(toward the sides) from a common central area 160. An anchor post
158a extends from the bottom side of at least some of the legs 158
(toward an overall bottom surface of the cleat component 154).
While it is not required, preferably each leg 158 will include at
least one anchor post 158a, and multiple anchor posts 158a may be
provided on at least some of the legs 158, if desired. Any desired
number of legs 158 (and/or any other desired types of traction
enhancing structures) and/or anchor posts 158a may be provided on
the cleat component 154.
[0056] As further shown in FIGS. 2A and 2B, this example cleat
component 154 further includes ridges 162 that extend between
adjacent legs 158. While it is not required, preferably each
adjacent pair of legs 158 will include at least one ridge 162, and
the ridge 162 may be continuous or discontinuous as it extends
between the legs 158. If desired, these ridges 162 may be formed to
include one or more recesses, grooves, or openings 164.
[0057] The anchor posts 158a, ridges 162, and/or openings 164
provide additional support and/or surface area for engaging the
cleat base 156, as will be described in more detail. As noted
above, production of the cleat 150 may include an initial step of
forming the cleat component 154, e.g., by an injection molding
process. One or more of the cleat components 154 thus formed then
may be placed in another mold (or the mold in which they are formed
may be modified), and the material of the cleat base 156 (e.g.,
nylon 66) may be molded around the material of the cleat component
154. In this additional molding step, the flowable material of the
cleat base 156 may be injected into the mold so that material of
the cleat base 156: (a) flows around and surrounds at least the
sides of the anchor post(s) 158a, (b) extends around the upper
surface, peripheral edge, and lower surface of the ridges 162, and
(c) extends into or through the recesses, grooves, or openings 164.
Once the material of the cleat base 156 is cured or hardened, it
forms a continuous, one piece structure around the anchor post(s)
158a and ridges 162 and through the openings 164 of the cleat
component 154 (thus "in-molding" the cleat component 154 into a
central opening left in the cleat base 156). This continuous
in-molded construction helps prevent undesired separation of the
cleat component 154 from the cleat base 156 irrespective of the
relative forces applied between these components (e.g., tensile,
pulling force, torsional force, etc.). In this illustrated
structure, as shown in FIGS. 2C-2E, the outer perimeter 156P of the
cleat base 156 forms an outermost perimeter of the overall cleat
structure 150.
[0058] Additional features of this example cleat structure 150 now
will be described. As shown in FIGS. 2C-2E, the cleat base 156 of
this example structure 150 is formed (e.g., during the in-molding
procedure mentioned above) to include a set of perimeter openings
156O or grooves located adjacent and inside the outer perimeter
156P of the cleat base 156. These openings 156O, which may vary
widely in numbering, positioning, shape, etc., provide support and
surface area for engaging the cleat 150 with a footwear sole
structure 104, as will be described in more detail below. In
addition, the bottom or interior surface of the cleat base 156 may
be formed to include one or more raised elements 156N (e.g., 0.5 to
4 mm high ridges, nubs, etc., see FIG. 2C), which also can provide
additional anchoring support for the cleat 150 to sole structure
104 engagement described in more detail below. The numbers,
locations, shapes, orientations, and/or relative positioning of the
openings or grooves 156O and/or raised elements 156N may be varied
widely without departing from this invention.
[0059] In the cleat structure 150 illustrated in FIGS. 2C-2E, an
entire bottom of the cleat 150 is located inside the outer
perimeter 156P of the cleat base 156, and this perimeter 156P
surrounds a single cleat structure 150. In at least some structures
in accordance with examples of this invention, at least 90% (and in
some examples, at least 95%) of an area of the bottom of the cleat
comprises: (a) a bottom surface of the cleat component 154, a
bottom surface of the cleat base 156, and the set of perimeter
openings 156O (see FIG. 2C). In such structures, at least 90% of a
combined surface area of the bottom surfaces of the cleat component
154 and the cleat base 156 (excluding the missing surface at
openings 156O) is planar, substantially planar, or smoothly curved,
and in some examples, at least 95% or even at least 98% of this
combined surface area is planar, substantially planar, or smoothly
curved. As a more specific example, as shown in FIG. 2C, the area
corresponding to the raised nubs 156N from the bottom surface of
cleat base 156 may constitute less than 5% (and in some examples,
less than 2%) of the combined bottom surface area of cleat base 156
and cleat component 154, and the bottom surfaces of the cleat base
156 and the cleat component 154 are planar, substantially planar,
or smoothly curved over their own surfaces and with respect to one
another. Notably, as evident from FIGS. 2C and 2E, the bottom of
this cleat structure 150 does not include a threaded base member or
a turnbuckle type releasable attachment structure.
[0060] FIGS. 2A through 2E illustrate additional features that may
be included in cleat structures 150 in accordance with at least
some examples of this invention. As shown in FIGS. 2A and 2B, the
cleat component 154 may be formed to include a central opening 166
(e.g., through the common central area 160). During the in-molding
process for forming the cleat 150, the flowable material of the
cleat base 156 may be injected into the mold so that a portion of
the cleat base 156 material extends to and is exposed to an outer
surface of the cleat 150 through the central opening 166. Thus, in
this central area 160, the portion of the cleat base 156 material
exposed at the outer surface of the cleat structure 150 through the
central opening 166 is surrounded by the material of the cleat
component 154. This feature also can help anchor the cleat
component 154 with the cleat base 156.
[0061] The portion of the cleat base 156 material exposed at the
outer surface of the cleat structure 150 through the central
opening 166 may have any desired color, shape, and/or orientation
without departing from this invention. For example, if desired, the
exposed cleat base 156 material at the central opening 166 may be a
different color from the surrounding cleat component 154 material
and may take on the shape of a logo, design, or word. Also, if
desired, the central area 160 of the cleat component 154 may have
plural openings 166 of this type.
[0062] As additional potential features, if desired, the exterior
or exposed surface of the cleat base 156 may include one or more
traction enhancing structures. In this illustrated example, the
exterior surface of the cleat base 156 includes traction enhancing
structures located between each adjacent pair of legs 158 of the
cleat component 154 (although more traction enhancing structures
may be provided, if desired). While any desired traction enhancing
structure may be used without departing from this invention, in the
illustrated example structure 156 shown in FIG. 2D, the exterior
surface of the cleat base 156 includes fin cleat elements 168
located between each pair of adjacent legs 158 of the cleat
component 154. These fin elements 168 are integrally formed in the
material of the cleat base 156 during the molding process at the
areas thereof that overlie the ridges 162 and openings 164 of the
cleat component 154.
[0063] As mentioned above, cleat structures 150, e.g., of the types
described above, may be incorporated into a sole structure 104 of
an article of footwear 100, such as engaged with an outsole
component 104b of the article of footwear 100. While this
engagement may take on a variety of forms, in one example of this
invention, one or more cleat structures 150 (e.g., of the types
described above) are permanently engaged with an outsole component
104b by an in-molding process. With the more specific cleat
construction 150 of the type described above, however (with a nylon
cleat base 156 and a TPU cleat component 154 engaged with it),
portions of the cleat 150 may be subject to deformation (e.g.,
melting, disfiguration, etc.) when processed under molding
conditions (e.g., time, temperature, and/or pressure) needed to
shape the material (e.g., synthetic rubber) of the outsole
component 104b. Accordingly, additional aspects of this invention
relate to mold structures and molding methods that allow in-mold
attachment of cleats 150 with an outsole component 104b, as will be
described in more detail below.
[0064] FIGS. 3A and 3B illustrate various features of a mold 300
according to at least some examples of this invention, e.g., for
forming a sole element of an article of footwear, such as an
outsole component (e.g., like component 104b with cleat element 150
in-molded therewith). The mold 300 includes a first mold component
302 (e.g., a mold plate) including a first portion of one or more
mold cavities 304 in which the outsole component is formed. As
shown in FIG. 3A, a single mold component 302 may include a
plurality of different mold cavities 304, which may be
interconnected or completely separated from one another. The first
portion(s) of the mold cavity 304 in this example mold structure
300 include a first area for forming a base footwear sole component
(e.g., outsole element 104b). As shown in FIG. 3A, the first area
includes a first molding surface 304A exposed in the mold cavity
304 made from a first material having a first thermal conductivity.
In the illustrated example, the first molding surface 304A is made
from a metal or metal alloy material, such as aluminum or aluminum
alloys, iron or iron alloys, steels, etc. In this illustrated
example, the first molding surface 304A includes indentations for
integrally forming the raised nub structures 152 described
above.
[0065] This same mold cavity 304 includes one or more cleat
receptacles 304B (ten total cleat receptacles 304B are shown in the
four separate mold cavities 304 of the mold 300 illustrated in FIG.
3A). The cleat receptacle 304B constitutes a second surface exposed
in the mold cavity 304 for engaging a previously formed cleat 150
(or other component to be in-molded into the base structure). The
cleat receptacle 304B of this illustrated example includes a
surface made from a second material having a second thermal
conductivity that is less than the first thermal conductivity of
the material of the molding surface 304A. In other words, the cleat
receptacle surface 304B is made from a material that does not heat
up as quickly as the material making up the molding surface 304A.
As some more specific examples, the cleat receptacle 304B (at least
its surface exposed in the mold cavity 304) may be made from one or
more of: a ceramic material (e.g., silica, alumina, zirconia,
carbides, borides, nitrides, silicides, etc.), a polymeric material
(e.g., a low thermal conductive polymer), and a polymeric material
including a ceramic, fiber, metal, or metal alloy powder dispersed
therein. As some more specific examples, the cleat receptacle
surface 304B may be made using an organic binder material that may
contain, for example, one or more of: (a) a mixture of an epoxy
(e.g., 10-15% by weight in component (a)), an amino resin compound
(e.g., 10-15% by weight in component (a)), and a filling agent
(e.g., a thickener in an amount of 70-75% by weight in component
(a)) and (b) a hardening agent. If desired, components (a) and (b)
above may be present in amounts of about 1:1 in the organic
binder.
[0066] The cleat receptacles 304B of FIGS. 3A and 3B constitute
"negatives" of at least some portions of the top surface of cleat
component 154 and cleat base 156 shown in FIGS. 2A-2E so that the
cleat structures 150 will securely fit in the cleat receptacles
304B while the outer perimeter flange or rim (e.g., a disk or
washer-like rim or edge) of the cleat structure 150 extends beyond
the edges of the cleat receptacle 304B. In this illustrated
example, the cleat receptacles 304B include recessed surfaces 358
for engaging and holding the legs 158 of cleat component 154 and
recessed surfaces 368 for engaging and holding the fin cleats 168
of cleat base 156. The recessed surfaces 358 and 368 prevent rapid
heat up of cleat component 154 and cleat base 158 during the
outsole molding process (because of their lower thermal
conductivity) and help prevent movement of the cleat structure 150
during the outsole molding process (e.g., when flowable outsole
material is injected into the mold 300).
[0067] When multiple cleat receptacles 304B are present in a single
mold cavity 304, the materials of the cleat receptacles 304B may be
completely separated from one another, e.g., the material of the
first molding surface 304A may form a continuous path between the
separated cleat receptacles 304B within a given mold cavity 304. In
such structures, the material of the molding surface 304A may
completely surround each individual cleat receptacle 304B.
Alternatively, if desired, a single cleat receptacle area 304B may
be sized and shaped so as to engage two or more cleat structures
150.
[0068] The mold 300 further may include a second mold component
including a second portion of the mold cavity (e.g., a plate with a
flat or shaped interior surface) for at least partially (and
optionally completely) covering the first portion of the mold
cavity 304. While the second mold component is not shown in the
figures, FIG. 3A illustrates hinge components 306 at which the
second mold component may engage the first mold component 302 in a
rotatable manner. If necessary, one or more intermediate plates may
be provided between the mold component 302 and the second mold
component, at least at some times during a molding procedure.
Alignment aids 308 help assure proper orientation and positioning
of the mold components with respect to one another as the mold 300
is closed during a molding process. The second mold component may
constitute a single plate, e.g., that completely covers all of the
mold cavities 304 and completely covers all of the cleat
receptacle(s) 304B. Optionally, if desired, the interior surface of
the second mold component (or an intermediate plate) may include
areas having a lower thermal conductivity (the same as or similar
to the material of receptacles 304B), e.g., at areas covering or
adjacent the cleat receptacles 304B.
[0069] One example of a molding procedure for attaching a component
to be in-molded (e.g., a cleat element 150) with another article
(e.g., an outsole component) is described below in conjunction with
FIGS. 3A-3G. First, starting with the mold structure 300 shown in
FIG. 3A, the mold 300 is closed (i.e., the mold components are
brought together by relative rotation on the hinges 306). One or
more intermediate plates may be provided between (and optionally
engaged with one or both of) the mold component 302 and the second
mold component. A first shot of outsole material (e.g., synthetic
rubber) then may be injected into the enclosed mold cavities 304 to
create a layer of outsole material 310 within the mold cavities 304
as shown in FIG. 3C. In this example process, the layer of outsole
material 310 completely covers the cleat receptacles 304B, although
an interior surface of the intermediate plate and/or the second
mold component (i.e., the surface located within the mold cavity
304 when the mold 300 is closed) may be shaped so as to prevent the
outsole material 310 from covering the cleat receptacles 304B, if
desired.
[0070] In the next step, as shown in FIG. 3D, the outsole material
310 is cleared off the areas above the cleat receptacles 304B to
thereby expose the cleat receptacles 304B within the mold cavities
304. This may be accomplished by cutting the outsole material 310
around each receptacle 304B, e.g., using a knife or blade. Then, as
shown in FIG. 3E, previously formed cleat elements 150 (e.g., as
shown in FIGS. 2C-2E) are fit into the cleat receptacles 304B so
that the bottom or interior sides of the cleat elements 150 face
the interior of the mold cavities 304. The outer perimeter or rim
of the cleat base 156 (including the openings 156O not shown in
FIG. 3E) may extend outward beyond the edges of the cleat
receptacles 304B. Also, while the downward oriented surface of the
outer perimeter or rim of the cleat base 156 may lie flush with (or
even press into) the surface of the already present outsole
material 310 in the mold cavities 304, in some examples of this
aspect of the invention, the downward oriented surface of the outer
perimeter or rim of the cleat base 156 may be somewhat elevated
with respect to the surface of the already present outsole material
310 in the mold cavities 304 (i.e., the cleats 150 may be fully
supported by the cleat receptacles 304B such that the cleat base
156 outer rim is suspended above the outsole material 310 in the
bottom of the mold cavities 304).
[0071] The mold 300 is then closed again and additional flowable
outsole material 310 (the same or different from that previously
introduced) is again introduced into the mold cavities 304. If
desired, as shown in FIG. 3F, sufficient moldable outsole material
310 may be introduced to completely cover the interior surfaces of
the cleat elements 150. This action further causes the flowable
outsole material 310 to cover and/or surround the outer perimeter
or rim of the cleat bases 156 and to flow through the openings 156O
through the rim to thereby permanently engage the cleats 150 with
the outsole material 310. Note, for example, area 312 in FIG. 3H (a
partial cut-away view of a portion of an outsole component 104b),
which shows the outsole material 310 extending around the perimeter
or rim of the cleat base 156 and through the openings 156O. The
flowable outsole material 310 introduced during this step may blend
with and form a continuous layer of material with the outsole
material 310 introduced earlier (e.g., during the step of FIG. 3C).
In this manner, a single, continuous layer of outsole material 310
completely covers and extends through the perimeter openings 156O
of the cleat base 156. The outsole material 310 extending through
the openings 156O and the surrounding/embedding of the raised areas
156N of the cleat base 156 into the outsole material 310 attach the
cleat 150 to the outsole material 310 in an "in-molded" manner.
[0072] The outsole material 310 then may be finally cured and/or
otherwise treated, and the combined outsole member 104b (including
the outsole material 310 and the in-molded cleat components 150)
may be removed from the mold 300 (e.g., as shown by FIG. 3G (for
improved clarity, the optional fraction enhancing nubs 152 are not
shown in FIG. 3G)). The curing or other post-molding treatments may
be performed while the combined outsole member 104b is located
within the mold 300 and/or after it is removed from the mold 300.
The combined outsole member 104b further may be engaged with a
midsole component 104a and/or otherwise engaged with an upper 102
or other structure to form an article of footwear (e.g., golf shoe
100).
[0073] The material of the cleat receptacles 304B helps prevent the
materials of the cleat structures 150 (e.g., the cleat component
154 and/or the cleat base 156) from melting and/or otherwise
deforming under the timing, heat, and/or pressure conditions used
for molding the outsole material 310 into the desired
configuration. As noted above, the materials at the surface of the
cleat receptacles 304B have a lower thermal conductivity, and thus
heat us less rapidly, than the material of the molding surfaces
304A of the mold cavities 304. This slowing of the heat transfer at
the cleat receptacle areas 304B helps keep the cleat structures 150
sufficiently cool during the molding process (and optionally also
during any curing and/or post-molding processes) to prevent melting
and/or deformation of the cleat structure 150.
[0074] As one more specific example, the TPU material of the
example cleat component 154 mentioned above may have a melting
point of about 170.degree. C., but under the temperature and
pressure conditions used during formation of the base outsole
component 104b (e.g., about 150.degree. C. and elevated pressure),
this TPU may begin to deform or melt at temperatures as low as
about 90.degree. C. The cleat receptacles 304B help keep the
temperature around the cleats 150 somewhat lower during the outsole
molding process (because the receptacle surfaces 304B heat up more
slowly) to decrease the likelihood of the TPU melting or deforming
during the molding process.
[0075] Many variations may be made from the specific molding
processes described above without departing from this invention.
For example, if desired, the cleat structures 150 could be set in
the cleat receptacles 304B before any moldable outsole material 310
is introduced into the mold cavity 304, and/or the moldable outsole
material 310 may be introduced in a single, molding step. This
option, however, may require the use of some type of support within
the mold cavity 304 (e.g., retractable pins) to hold the cleat
structures 150 in the proper position while the moldable material
310 is being introduced (e.g., so that the flowing moldable
material 310 does not tilt, knock askew, or otherwise affect
positioning of the cleat structures 150). Such support structures
also may be used in the processes of FIGS. 3A-3F, if necessary or
desired.
[0076] Additionally, while the discussion of the mold structures
and molding methods above relate primarily to production of cleated
sole structures, features of these aspects of the invention may be
applied to in-molding components other than cleats and/or footwear
outsole components. Rather, aspects of this invention may be
applied to molding any types of articles with in-molded components,
and particularly to molding articles in which the base component to
be molded must be processed under temperature, pressure, and/or
timing conditions that could result in melting, deformation, and/or
other types of damage to the in-molded component(s).
[0077] FIGS. 4A-4D illustrate further advantages potentially
available in cleats and cleated sole structures in accordance with
at least some examples of this invention. FIGS. 4A and 4B
illustrate a partial cut-away perspective view and a cross
sectional view, respectively, of an existing removable golf cleat
element 402 engaged with a golf shoe sole structure (including a
midsole element 404a and an outsole element 404b), while FIGS. 4C
and 4D show similar views of a golf cleat element 150 in-molded
with an outsole component 104b in accordance with at least some
examples of this invention. As evident from these figures, an
interior side of the known removable cleat element 402 includes a
turnbuckle type connection system 402a for releasably connecting
the cleat element 402 with corresponding connection structures 402b
provided in (e.g., engaged with) the outsole element 404b. In
addition to the added expense and manufacturing issues involved in
incorporating these additional connection structures into a golf
shoe, the turnbuckle connection system 402a of the cleat 402 and
the connection structures 402b of the outsole 404b project upward
toward the wearer's foot. As shown in FIG. 4B, the height H.sub.1
of the outsole component 404b from the bottom surface 406B to the
top surface 406T at and around the cleat engagement area is
relatively high (e.g., typically at least about 8 mm) to
accommodate the additional turnbuckle engagement structures 402a,
402b needed in the outsole 404b.
[0078] These turnbuckle connection system structures 402a, 402b
also are relatively hard and stiff in order to prevent deformation
and to assure a reliable connection between the cleat 402 and the
sole structure 404b. Therefore, the turnbuckle connection system
structures 402a, 402b may apply significant pressure points and
discomfort to the wearer's foot (particularly in view of the
distances walked while playing a round of golf). Footwear
manufacturers attempt to moderate the feel of these types of cleats
either by adding significant midsole foam 404a (or other material)
over the cleat areas or by covering the cleat areas with a rigid
moderator plate (in an effort to disperse the load over a larger
area of the foot). These features increase the overall height of
the sole structure and/or reduce flexibility and/or natural feel of
the shoe.
[0079] The cleat and sole structures in accordance with at least
some examples of this invention, on the other hand, as shown in
FIGS. 4C and 4D, avoid some of these issues with the known cleats.
As described above, by using the in-molded connection/attachment
features, the overall bottom or interior surface of cleats 150 in
accordance with at least some examples of this invention are
planar, substantially planar, and/or smoothly contoured.
Additionally, the cleats 150 (and particularly the outer perimeter
or rim area of the cleat base 156) may be made from materials that
allows the cleat bottom surface to flex under an apply load (e.g.,
to better conform to the applied load shape). These features help
avoid or reduce application of point load forces to the bottom
plantar surface of the wearer's foot and help avoid or reduce the
need for moderator plates and/or quite thick midsole material and
midsole height to moderate the feel of the cleat 150. This
flexibility likewise may enable the cleat base to flex as force is
placed on the overall sole component, which may help the cleat to
bend with the rubber or other material of the sole component rather
than remaining stiff and unbent and pulling away from the material
of the sole component (thereby tearing or breaking the rubber or
other material holding the sole to the cleat). Sole structures in
accordance with at least some examples of this invention also may
have a reduced weight due to the reduced amount(s) of outsole
and/or midsole material.
[0080] Additionally, the in-molded attachment features of cleats
150 in accordance with at least some examples of this invention
avoid the need for turnbuckle, threaded, or other releasable cleat
attachment features. This also helps avoid the point load features
described above. Also, as illustrated in FIG. 4D, this feature
allows the overall height H.sub.2 of the outsole component 104b
from the bottom surface 408B to the top surface 408T at and around
the cleat engagement area to be made lower. The base outsole
component thickness H.sub.2 at and around the cleat engagement area
may be made to be less than 7 mm (exclusive of the height of any
raised nubs or other traction elements integrally formed in the
outsole), and in some examples, less than 5 mm. In the illustrated
example structure of FIG. 4D, the base outsole component thickness
H.sub.2 (exclusive of the height of any raised nubs or other
traction elements integrally formed in the outsole) is about 4 mm.
Therefore, the overall sole structure 104 of articles of footwear
according to at least some examples and aspects of this invention
may be made with a smaller overall height, a lower profile, and a
more flexible construction. Aspects of sole structures in
accordance with at least some examples of this invention may allow
production of a more natural motion golf shoe (or other cleated
shoe) construction.
[0081] As some additional potential advantages, the in-molding
procedures for making the cleat structure 150 and/or the outsole
component 104b may avoid the need to use primers, cements, or
adhesives (or other chemicals, e.g., to engage the cleat component
154 with the cleat base 156 and/or to engage the cleat 150 with the
base outsole material 104b). Thus, easier, cost-effective, and more
environmentally friendly production processes may be used (as
compared with processes that use of primers, adhesives, and/or
cements). Alternatively, if desired, the in-molding processes
described above could be used along with use of at least some
amount of primers, adhesive, or cements (optionally, however, a
reduced amount as compared to conventional processes, e.g., to
better hold the parts in place at least during the initial phases
of the production processes).
[0082] III. Conclusion
[0083] The present invention is disclosed above and in the
accompanying drawings with reference to a variety of embodiments.
The purpose served by the disclosure, however, is to provide
examples of the various features and concepts related to the
invention, not to limit the scope of the invention. Those skilled
in the art will understand that the structures, options, and/or
alternatives for the cleat structures, sole structures, footwear
structures, molds, and/or molding methods described herein,
including the features of the various different embodiments of the
invention, may be used in any desired combinations,
subcombinations, and the like, without departing from the
invention. Those skilled in the relevant art also will recognize
that numerous variations and modifications may be made to the
embodiments described above without departing from the scope of the
present invention, as defined by the appended claims.
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