Sole board

A sole board for an article of footwear includes a plate that has a forefoot region, a midfoot region, and a heel region. The sole board includes a channel disposed in a top surface of the plate in the forefoot region. The channel extends from a lateral edge of the plate to a medial edge of the plate. A characteristic of the channel at the lateral and medial edges of the plate is different than the characteristic of the channel at a middle of the channel.

BACKGROUND

Field

Embodiments of the present invention relate generally to a sole board for an article of footwear; and more specifically to a sole board with a channel.

Background

Individuals can be concerned with the amount of cushioning, support, or flexibility an article of footwear provides. This is true for articles of footwear worn for non-performance activities, such as a leisurely stroll, and for performance activities, such as running, because throughout the course of an average day, the feet and legs of an individual are subjected to substantial impact forces. When an article of footwear contacts a surface, considerable forces may act on the article of footwear and, correspondingly, the wearer's foot.

The human foot is a complex and remarkable piece of machinery, capable of withstanding and dissipating many impact forces. The natural padding of fat at the heel and forefoot, as well as the flexibility of the arch, help to cushion the foot. Although the human foot possesses natural cushioning and rebounding characteristics, the foot alone is incapable of effectively overcoming many of the forces encountered during every day activity. Unless an individual is wearing footwear that provides proper cushioning, support, and flexibility, the soreness and fatigue associated with every day activity is more acute, and its onset accelerated. The discomfort for the wearer that results may diminish the incentive for further activity. Also, inadequate cushioning, support, or flexibility in an article of footwear can lead to injuries such as blisters; muscle, tendon, and ligament damage; and bone stress fractures. Improper footwear can also lead to other ailments, including back pain.

BRIEF SUMMARY

Sole boards for articles of footwear are disclosed. In some embodiments, a sole board for an article of footwear includes a plate that has a forefoot region, a midfoot region, and a heel region. In some embodiments, the sole board includes a channel disposed in a top surface of the plate in the forefoot region. In some embodiments, the channel extends from a lateral edge of the plate to a medial edge of the plate. In some embodiments, a characteristic of the channel at the lateral and medial edges of the plate is different than the characteristic of the channel at a middle of the channel.

In some embodiments, the characteristic is a depth of the channel. In some embodiments, the characteristic is a width of the channel. In some embodiments, the width of the channel at the lateral and medial edges of the plate is greater than the width of the channel at the middle of the channel. In some embodiments, the width of the channel at the lateral and medial edges of the plate is at least twice the width of the channel at the middle of the channel. In some embodiments, the width of the channel at the lateral edge of the plate is equal to the width of the channel at the medial edge of the plate. In some embodiments, the width of the channel at the middle of the channel is 1.2 millimeters. In some embodiments, the width of the channel at the medial and lateral edges of the plate is 2.5 millimeters. In some embodiments, the channel extends along a metatarsal region in the forefoot region.

In some embodiments, the sole board also includes a lasting hole disposed in the midfoot region of the plate. In some embodiments, the sole board also includes a plurality of indents disposed in the top surface of the plate. In some embodiments, the plurality of indents forms a honeycomb pattern.

In some embodiments, a thickness of the plate tapers in the forefoot region. In some embodiments, a maximum thickness of the plate is five millimeters. In some embodiments, a minimum thickness of the plate is 1.5 millimeters.

In some embodiments, the plate includes a non-woven fabric. In some embodiments, the plate includes a plastic. In some embodiments, the plate includes polypropylene. In some embodiments, the plate includes a layer of a non-woven fabric and a layer of polypropylene. In some embodiments, the plate includes a layer of polypropylene disposed between two layers of a non-woven fabric.

In some embodiments, the sole board is an insole. In some embodiments, the sole board is a sock-liner. In some embodiments, the sole board is a cleat frame structure. In some embodiments, the cleat frame structure has cleats that extend from a bottom of the plate. In some embodiments, the sole board also includes a second plate disposed below the plate. In some embodiments, the sole board also includes a second channel disposed in a top surface of the second plate in the forefoot region underneath the channel in the plate.

DETAILED DESCRIPTION

The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings, in which like reference numerals are used to indicate identical or functionally similar elements. References to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

The term “invention” or “present invention” as used herein is a non-limiting term and is not intended to refer to any single embodiment of the particular invention but encompasses all possible embodiments as described in the application.

Embodiments of the present invention provide a sole board for articles of footwear. In some embodiments, a sole board may provide desired flexibility and stiffness for an article of footwear. In some embodiments, the sole board may be designed for a particular activity or a specific movement within that activity. For example, in some embodiments, the sole board may be used in articles of footwear used for various athletic activities or sports, such as football, soccer, baseball, basketball, running, walking, etc. Because specific movements in these or other sports may require a high amount of flexion, the article of footwear should be flexible enough to accommodate this flexion. At the same time, the article of footwear should also provide appropriate stiffness to protect a wearer's foot, for example, from injuries, such as hyperextension of the toes (i.e., turf toe). In addition, while a wearer is not engaged in specific movements that require a high amount of flexion, such as when the wearer is simply walking or running, the article of footwear should be more flexible and less stiff.

In some embodiments, the sole board comprises a plate configured to be disposed within an article of footwear as an insole or sock-liner. The sole board may be disposed between the midsole of the article of footwear and the wearer's foot. In some embodiments, the sole board may be removably inserted in the article of footwear. In some embodiments, the sole board may be fixedly attached to the article of footwear. In some embodiments, the sole board may have an upper surface contoured to receive the wearer's foot, thus forming a contoured footbed. In some embodiments, the sole board comprises a plate configured to be disposed on a bottom portion of the article of footwear, for example, as a cleat frame structure.

In some embodiments, the sole board (e.g., sock-liner, insole, or cleat frame structure) may include a channel in the top surface of the plate. In some embodiments, the channel may be disposed in a forefoot region of the sole board. For example, the channel may be disposed in a metatarsal region of the sole board (i.e., the region of the sole board that lies directly underneath the metatarsal bones of the wearer's foot when the article of footwear is worn). In some embodiments, the channel extends from a medial edge of the plate to a lateral edge of the plate. In some embodiments, the channel has a characteristic, such as a width or a depth, that is different at the medial edge and the lateral edge of the plate than in a middle of the plate. For example, the width of the channel at the medial edge and the lateral edge of the plate may be greater than the width of the channel at the middle of the plate. In some embodiments, the height or thickness of the sole board tapers towards the front of the plate.

A sole board10, as shown, for example, inFIGS. 1-12, comprises a plate12. While these figures show sole board10as a sole board for the right foot, it is to be understood that the sole board for the left foot would have similar features and may be a mirror image of the sole board depicted. In some embodiments, plate12comprises a forefoot region14, a midfoot region16, and a heel region18. In some embodiments, plate12comprises a medial edge22and a lateral edge24. In some embodiments, sole board10comprises an insole.

In some embodiments, plate12comprises a plastic. For example, plate12may comprise polypropylene. In some embodiments, plate12comprises a non-woven fabric. In some embodiments, plate12is made of multiple materials. In some embodiments, plate12comprises layers of different material. In some embodiments, plate12comprises a layer of non-woven fabric and a layer of polypropylene. In some embodiments, plate12comprises a layer of polypropylene disposed between two layers of non-woven fabric. In some embodiments, plate12comprises metal composites. For example, plate12may comprise steel composites. In some embodiments, plate12comprises a foam. For example, plate12may be made of polyurethane foam, ethyl vinyl acetate, or other foam composites. In some embodiments, plate12comprises thermoplastic polyurethane. In some embodiments, plate12comprises a nylon-based composite or other composite.

In some embodiments, plate12has a height or thickness that varies. In some embodiments, plate12has a maximum thickness of 5 millimeters. In some embodiments, plate12has a minimum thickness of 1.5 millimeters. In some embodiments, the thickness of plate12tapers in forefoot region14, as shown, for example, inFIGS. 4-6. In some embodiments, the minimum thickness of plate12is disposed at the front of forefoot region14(i.e., at the toe). In some embodiments, the tapering in forefoot region14contributes to increased flexibility at lower amounts of bend of sole board10and increased stiffness at higher amounts of bend of sole board10(e.g., above 55 degrees of bending).

In some embodiments, sole board10comprises a channel20, which may also be referred to as a groove. In some embodiments, channel20is disposed on a top surface of plate12. In some embodiments, channel20is disposed in forefoot region14. In some embodiments, channel20is disposed within forefoot region14at the region of plate12that lies directly underneath the metatarsal bones of the wearer's foot with the article of footwear is worn (i.e., metatarsal region15), as shown, for example inFIGS. 1 and 2. Thus, channel20may extend laterally along metatarsal region15in forefoot region14from medial edge22to lateral edge24. In some embodiments, channel20allows for greater flexibility of sole board10during initial bending (e.g., up until the sides of channel20come in contact with each other), and provides less flexibility and greater stiffness of sole board10during later bending (e.g., after the sides of channel20come in contact with each other), as will be described more fully below.

In some embodiments, channel20may have a V-shaped cross section. In some embodiments, channel20may be curved (i.e. nonlinear). In some embodiments, channel20may be linear. In some embodiments, from a z-axis perspective (e.g., from a rear cross-sectional view), the end portions of channel20(i.e., at medial edge and/or lateral edge24) may be higher than a middle portion of channel20given the contour of the footbed. Thus, in some embodiments, channel20may appear linear from one perspective (e.g., a top planar view, as inFIG. 2) but be curved to follow the contour of the footbed.

In some embodiments, as shown, for example, inFIGS. 3-12, plate12comprises a projection44that extends from a bottom surface of plate12. In some embodiments, projection44is spaced from the outer edges of plate12, such as medial edge22and lateral edge24. In some embodiments, projection44provides additional cushioning for the wearer's foot. In some embodiments, projection44varies in width along the length of plate12. For example, projection44may be wider in forefoot region14(seeFIGS. 7 and 8) than in midfoot region16(seeFIGS. 9 and 10) and heel region18(seeFIGS. 11 and 12).

In some embodiments, sole board10comprises a lasting hole30through plate12, as shown inFIGS. 1-3. In some embodiments, lasting hole30is disposed in midfoot region14. In some embodiments, lasting hole30is disposed in the center of sole board10. In some embodiments, lasting hole30has a radius between 3 and 4 millimeters. For example, lasting hole30may have a radius of 3.5 millimeters. In some embodiments, lasting hole30facilitates easier lasting of the article of footwear.

In some embodiments, sole board10comprises a plurality of indents40disposed on a top surface of plate12. In some embodiments, plurality of indents40forms a honeycomb pattern, as shown, for example, inFIGS. 1 and 2. In some embodiments, plurality of indents40extends from forefoot region14to heel region18. In some embodiments, plurality of indents40may include a logo42. In some embodiments, logo42is disposed in heel region18.

As noted above, channel20may allow for increased flexibility of sole board10during initial phases of bending, yet provide increased support during later phases of bending (i.e., after the sides of channel20begin to contact each other). In some embodiments, channel20extends from medial edge22to lateral edge24. In some embodiments, channel20has a characteristic that may vary from medial edge22to lateral edge24. In some embodiments, the characteristic is a depth of channel20. In some embodiments, the depth of channel20may be different at medial edge22and lateral edge24than the depth of channel20at a middle of channel20. For example, the channel20may be deeper at medial edge22and lateral edge24than at the middle of channel20. In some embodiments, the depth of channel20may be less at medial edge22and lateral edge24than at the middle of channel20.

In some embodiments, the characteristic is a width of channel20. In some embodiments, the width of channel20at medial edge22and lateral edge24is different than the width of channel20at the middle of channel20. In some embodiments, the width of channel20is greater at medial edge22and lateral edge24than at the middle of channel20, as shown, for example, inFIG. 13. In some embodiments, the width of channel20may be less at medial edge22and lateral edge24than at the middle of channel20. In some embodiments, the middle of channel20is a portion of channel20that is intermediate medial edge22and lateral edge24. In some embodiments, the middle of channel20is the lateral center point along channel20between medial edge22and lateral edge24. In some embodiments, the middle of channel20is a portion of channel20surrounding and including the lateral center point. For example, in some embodiments, the width of channel20at medial edge22and lateral edge24is at least twice the width of channel20at the middle of channel20. In some embodiments, the width of channel20at medial edge22is the same as the width of channel20at lateral edge24. In some embodiments, the width of channel20is greater at one of the medial edge22and lateral edge24than the middle of channel20and/or the other of the medial edge22and lateral edge24to provide targeted increased support.

In some embodiments, the width of channel20at the middle of channel20is between 1 and 1.5 millimeters. For example, the width of channel20at the middle of channel20may be 1.2 millimeters. In some embodiments, the width of channel20at medial edge22and lateral edge24is between 2 and 3 millimeters. For example, the width of channel20at medial edge22and lateral edge may be 2.5 millimeters. In some embodiments, the width of channel20gradually increases from the middle of channel20to medial edge22and lateral edge24.

In some embodiments, by having a greater width at medial edge22and lateral edge24than in the middle of channel20, the sides of channel20at medial edge22and lateral edge24do not contact each other until later in the bending cycle of sole board10. This arrangement, as shown, for example, inFIGS. 14-16, allows for greater contact between the sides of channel20at the middle of channel20and helps distribute stress from the bending of sole board10across a greater area, which may result in increased stiffness as sole board10bends. Thus, sole board10and channel20allow for dynamic flexibility during walking and running that does not require a high amount of flexion, while also providing increased stiffness as sole board10bends to help prevent hyperextension of the wearer's toe.

FIG. 17illustrates the benefit of having the width of channel20greater at medial edge22and lateral edge24than at the middle of channel20in graph50. Graph50shows the moment required to bend sole board10to a particular angle. Graph50includes line52, which shows the results for a sole board without a channel, and line54, which shows the results for sole board10with channel20. The slope of lines52and54show the rotational stiffness. As seen in graph50, the rotational stiffness of sole board10with channel20is less than the sole board without a channel, thus making sole board10more flexible during movement that does not require high amounts of flexion. However, at larger angles (e.g., above 55 degrees), the rotational stiffness of sole board10with channel20is greater than the sole board without a channel, thus making sole board10less flexible and more stiff to protect the wearer's toes from hyperextension during movements that may require high amounts of flexion.

As noted above, in some embodiments, a sole board comprises a cleat frame structure. For example, a sole board110, as shown inFIG. 18, may comprise a cleat frame structure. In some embodiments, sole board110comprises a plate112with a channel120. In some embodiments, channel120is disposed in a similar location on plate112as channel20on plate12. In some embodiments, channel120is shaped similarly to channel20. For example, channel120may vary along its length such that a width of channel120at a middle of channel120is different than a width of channel120at medial edge122and lateral edge124. In some embodiments, sole board110may be similar in design as sole board10and may include any of the features discussed above with respect to sole board10. In some embodiments, sole board110comprises cleats130extending from a bottom of plate112. In some embodiments, plate112comprises thermoplastic polyurethane. In some embodiments, plate112comprises a nylon-based composite or other composite.

As noted above, in some embodiments, a sole board comprises a sock-liner. For example, a sole board210, as shown inFIG. 19, may comprise a sock-liner. In some embodiments, sole board210comprises a sock-liner that is fixedly disposed in an upper of an article of footwear. In some embodiments, sole board210comprises a sock-liner that is detachably disposed in an upper of an article of footwear. In some embodiments, sole board210comprises a plate212with a channel220. In some embodiments, channel220is disposed in a similar location on plate212as channel20on plate12and channel120on plate112. In some embodiments, channel220is shaped similarly to channel20and channel120. For example, channel220may vary along its length such that a width of channel220at a middle of channel220is different than a width of channel220at medial edge222and lateral edge224. In some embodiments, sole board210may be similar in design as sole board10and may include any of the features discussed above with respect to sole board10. In some embodiments, plate212comprises a foam. For example, plate212may be made of polyurethane foam, ethyl vinyl acetate, or other foam composites.

In some embodiments, an article of footwear comprises only one of sole board10, sole board110, and sole board210(e.g., only one of an insole, cleat frame structure, and sock-liner that has a channel or groove). In some embodiments, an article of footwear comprises any combination of sole board10, sole board110, and sole board210. For example, as shown inFIG. 20, an article of footwear may comprise each of sole board10, sole board110, and sole board210(i.e., an insole, cleat frame structure, and sock-liner that each have a channel or groove). In some embodiments, channels20,120, and220may be aligned with each other such that channel20is underneath channel120and channel220is underneath channels20and120.

Various embodiments described herein allow for appropriate amounts of flexibility and stiffness in an sole board at various angles of bending, thus facilitating flexion of the wearer's foot during specific movements of athletic activity (i.e., walking, running, etc.), but preventing hyperextension of the wearer's toes. Further variations of the embodiments described above may also be provided.