Patent Description:
Cleated footwear is used in a variety of sports such as soccer, American football, rugby, golf, baseball, lacrosse, high jump, running etc. to provide improved grip for an athlete especially on slippery or soft ground. Cleated footwear is subject to particularly high mechanical forces and torques. For this reason, the production of cleated footwear represents challenges not encountered in the production of non-cleated footwear.

It is a firm belief in the prior art that the sole of cleated footwear should therefore be formed of a single piece. As a consequence, the production methods are rather inflexible and the ways to modify an existing article of footwear to adapt it for different requirements based on, for example, the anatomy of the athlete, the sport, the surface properties of the sports ground (e.g. hard, soft, artificial turf) are very limited. Entirely new outsoles have to be designed and manufactured for different models of an article of footwear which is a costly and time-consuming process. Furthermore, an insole board, also known as a lasting board, is typically required to provide sufficient mechanical performance, which adds to the weight of the article of footwear and the complexity of the production process as an upper has to be attached to both the lasting board and the outsole.

Existing solutions to individualize cleated footwear involve exchanging the studs one by one and/or the upper. <CIT> discloses a studded sports shoe comprising a sock-like upper with an upper side and a lower side, a chassis releasably arranged in the interior of the upper and a plurality of studs, wherein each stud is releasably attached to the chassis through the lower side of the sock-like upper. The disadvantage of this method is that this assembly process is slow and complex. Furthermore, it requires an insole or lasting board and therefore the resulting article of footwear is heavy and has a higher profile than desirable. Furthermore, single studs can get lost easily.

An alternative approach is described in <CIT>, which discloses a modular shoe, with a sock like outer shoe and a frame. The sock like outer shoe is provided for a releasable arrangement around the frame. The sock like outer shoe may comprise a plurality of profile elements, wherein at least one of the profile elements extends from an outer side of the sock like outer shoe. A region of the at least one of the profile elements may be configured to releasably engage in a formfitting manner with a lower side of the frame of the modular shoe. The disadvantage of this approach is a lower stability of the outer shoe compared with conventional cleated footwear as well as the added weight and increased profile due to the sock like outer shoe.

Several approaches are known in the prior art that use different types of studs in different regions of the sole. <CIT> discloses an article of footwear that may include an upper and a sole structure fixedly attached to a bottom portion of the upper. The sole structure may include a sole component including a baseplate having a bottom surface and at least a first ground engaging member extending substantially downward from the bottom surface of the baseplate, the first ground engaging member having a substantially circular cross-sectional shape. <CIT> discloses an article of footwear including a sole structure with multiple cleat systems. A first cleat system has a first cleat design and one or more cleat member sets that are tuned to provide different levels of traction and flexibility to different regions of the sole structure. A second cleat system has a second cleat design and is disposed on the sole structure in a location to provide maximum traction for various playing surfaces. The sizes, material properties and arrangement of each cleat system are varied.

It is also known that the lasting board can be integrally formed with the molding material to reduce the height profile of the article of footwear. <CIT> discloses a golf shoe including a sole member integrally formed with a molding material, a structural member, and a plurality of receptacles in the bottom of the sole member. The structural member extends along at least a portion of the length of the sole member and is configured to not vertically overlap with any of the receptacles. The shoe disclosed in <CIT> cannot be individualized easily as the lasting board is integrally formed with the molding material. The upper is not lasted directly onto the structural member but instead an additional molding member is required which adds to the complexity and cost of the manufacturing process and increases the weight of the shoe.

It is known in the prior art that a sole of an article of non-cleated footwear can be formed from several pieces. <CIT> discloses a two piece shoe bottom construction including a platform structure and a heel structure. The platform structure has a forward toe support portion and a rear raised portion. The rear raised portion being elevated substantially above the toe portion so that it will correspond to a particular height of a heel portion. <CIT> discloses an article of footwear including an upper and a sole assembly. The sole assembly includes a first member that is coupled to the upper and a second member that is moveably coupled to the first member.

Further technical aspects are described in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>.

<CIT> is directed to an article of footwear including a lasting board that may have a ground side surface and a foot side surface opposite the ground side surface. The ground side surface of the lasting board may have a peripheral area extending along a peripheral edge of the lasting board. The ground side surface of the lasting board may have a central area disposed inside of the peripheral area. The article of footwear may include an upper secured to the peripheral area of the ground side surface of the lasting board.

<CIT> is directed to an article of footwear. The article of footwear may include an upper configured to receive a foot and a sole structure fixedly attached to the upper and including a sole component having a ground-engaging lower surface. The sole structure may further include a chassis configured to provide support to the sole component, wherein the chassis includes a forefoot region, a midfoot region, a heel region, a lateral width, a longitudinal axis, and a reinforcing rib disposed longitudinally and having a length along the longitudinal axis.

In view of the prior art, there is a considerable need for a novel lightweight yet sturdy article of cleated footwear that can be manufactured in a more flexible and cost-efficient manner.

This problem is solved in the present invention by an article of cleated footwear comprising: an outsole plate comprising (i) a rigid first member, extending substantially along the length of the outsole, and (ii) a rigid second member, (iii) wherein the second member is attached to the first member, and (iv) wherein the first member and / or the second member has a ground-engaging profile; and an upper attached to the first member.

The first member is also called "chassis" and the second member is also called "skin". An article of cleated footwear in the present context has a ground-engaging profile which is to be understood to be any profile whose purpose it is to improve the grip of the sole by partly penetrating the ground. For example, the ground-engaging profile could comprise studs such as studs for football boots, spikes such as spikes for running shoes, studs for hiking or walking boots, or any other textured profile whose purpose it is to partly penetrate the ground and thus to improve the grip of the sole. The term ground-engaging profile here does not apply to a sole element whose purpose it is to simply make touching contact with the ground, for example any part of the sole of high-heeled shoes as these are not intended to partly penetrate the ground in order to improve the grip.

The first member and the second member may have a ground-engaging profile in which case both the first member and the second member provide grip and stability. Alternatively, just the second member may have a ground-engaging profile in which case the second member provides grip and the first member provides stability. Alternatively, just the first member may have a ground-engaging profile in which case the first mem-ber provides grip and stability, and the second member improves the stability in those regions where it is most required.

The upper may be attached to the first member by any suitable means such as, for example, by means of an adhesive or by welding. The first member may be attached to the second member by any suitable means such as, for example, by means of an adhesive or by welding.

The first member is rigid and extends substantially along the length of the outsole of the article of footwear. Thus, the length of the first member is preferably at least <NUM>% of the length of the outsole of the article of footwear, more preferably at least <NUM>%, most preferably <NUM>%, wherein the length is measured along a longitudinal direction of the outsole of the article of footwear. The first member therefore serves as the primary element for providing a structure to the outsole. Unlike an insole or lasting board, the first member may have a first ground-engaging profile. The first member therefore may have both the structural function of an insole or lasting board in that it provides rigidity to the sole, but the first member may further provide some of the grip properties of the outsole. The use of a first member therefore allows a simpler and more lightweight construction than a conventional insole board combined with a second element with an outsole profile. With this construction, an insole board is not required, which simplifies the construction of the sole, saving processing time and costs and leads to an article of footwear with a lower total weight without sacrificing mechanical performance. The inventors have discovered that a weight reduction is possible due to this improved construction.

The second member preferably has a longitudinal length of at least <NUM>% of the length of the first member, more preferably <NUM>%. It is to be understood that the second member is not merely a stud. A function of the second member is to provide an ideal level of grip for the athlete whilst maintaining a low weight and good wearing comfort. The second member can be constructed to suit any particular sport or surface of sports grounds. Thus, during production, the same type of first member can be used for articles of footwear of different type (e.g. soccer shoe, rugby shoe, etc.), while only the second member is varied. This is contrary to conventional cleated footwear, for which, starting from a particular shoe, the entire soleplate has to be re-designed and manufactured even for a similar shoe that is used on a different surface (e.g. hard, soft, artificial turf), a different sport, or by a different type of athlete (e.g. beginner, ambitious amateur, professional, etc.).

Another advantage of this construction lies in the modular nature of the sole plate which simplifies the assembly of said soleplate by the manufacturer, for instance at a factory or at a store. Each piece, the first member and the second member, could be made from different materials and undergo different treatment to achieve particular mechanical or design properties. It is also feasible that a customer can easily and flexibly modify the article of cleated footwear after purchase. Thus, a customer does not have to purchase an entirely new shoe for a new activity, resulting in a favorable environmental impact.

Summarizing the above, an article of footwear according to the invention is of low weight is easy to assemble, can be individualized and modified quickly and at low cost, resulting in cost savings and a favorable environmental impact. The modularity of the sole plate results in a flexible and cost-efficient manufacturing process. Such articles of footwear could be used in a variety of sports, comprising football (soccer), American football, lacrosse, baseball, rugby, golf, running, high jump, or any other sport or activity requiring cleated footwear.

A first part of the upper may be lasted around a first region of the first member; and the second member may be attached to the first member such that at least a portion of the first part of the upper is arranged between the first member and the second member in at least a portion of the first region.

This arrangement is also referred to as board lasted as it is preferably carried out while the upper is arranged on a last and the first member (the board) arranged between a portion of the upper and the last. In order words, the upper is lasted around the first member and "sandwiched" between the first and the second member. The upper is then attached to the first and/or the second member by gluing and/or welding, and/or any other suitable means. In this construction, the connection of the sole and the upper is particularly stable and the risk of the upper tearing off is greatly reduced. This arrangement also allows to directly last the upper onto the first member in the first region. This makes an insole board redundant and reduces the number of components and the weight of the article of footwear while maintaining good mechanical stability.

This construction also prevents the formation of wrinkles in the toe area of the upper which is a frequent problem in cleated footwear where the tooling toe lip is low. As the upper is lasted around the first member, the rigid first member maintains sufficient tension in the upper in order to prevent the formation of wrinkles.

A second part of the upper may be sewn to a sheet and the sheet may be attached to a second region of the first member. For example, the upper could be sewn using a Strobel sewing machine. The sheet-like material could be made from a synthetic material, leather, and / or a textile. The sheet-like material may be from the same material as the upper, or any other suitable material. It is also feasible that the upper is directly sewn to the first member. This construction allows the overall weight of the article of footwear to be reduced as it is more lightweight than the configuration in the first region. It is also faster and easier to assemble the article of footwear in this second region than to perform the board lasting in the first region.

The second member of the outsole plate may extend over at least a portion of the second region and a portion of the first region, such that the second member covers the transition point between the second region and the first region.

It is functional if the second member extends over the transition point on the first member at which the method of attachment of the upper changes from lasting to being sewn. It is beneficial if this transition point is covered by the second member because the upper could tear at this point or detach from the first member. The transition point must be carefully selected because if the board lasting is cut off too early, that is if the board lasted area is too short, the interface between the second member and the first member won't be flush at the transition point which is required for the mechanical stability, especially of cleated footwear. If, however, the board lasted area is too long, the weight of the article of footwear is increased unnecessarily.

The second region may comprise a heel region and/or a shank region of the article of cleated footwear; and /or the first region may comprise a forefoot region of the article of cleated footwear.

To reduce stud tip pressure on the foot, it is beneficial that the upper is lasted around the first member in a forefoot region of the first member.

The sheet to which the upper may be sewn in the second region may comprise a cut-out region. The inventors have found that it is possible to still provide a stable connection of the upper to the first member if the sheet comprises a cut-out region. A cut-out region is an area in the sheet where a hole is formed in the sheet or where the material of the sheet is thinner than in another region. Preferably the cut-out region is at the center of the sheet. A hole may be cut into the sheet before or after sewing the upper to the sheet. Alternatively, a hole could be formed in the sheet while the sheet is produced. Another alternative is that the material of the sheet it made thinner in part of the sheet by mechanical means such as grinding or by chemical means such as etching. The cut-out region reduces the weight of the article of footwear.

The sheet may comprise a synthetic material, leather, and / or a textile. The sheet may be from the same material as the upper. These materials are advantageous because they are durable and prevent the upper from tearing where it is sewn to the sheet and provide a comfortable level of cushioning.

The sheet may be attached to the first member by means of an adhesive and / or by welding. An adhesive is a simple way of forming a strong and permanent bond. If the materials used allow welding, then welding may be a preferred method as it does not require the use of an additional adhesive, yet allows a strong bond to be formed.

The first member may comprise a first ground-engaging profile, which comprises at least one stud of a first type; and/or the second member may comprise a second ground-engaging profile, which comprises at least one stud of a second type.

The advantage of such a configuration is that an optimal grip can be achieved by allowing different types of studs for different parts of the foot. For instance, one could choose relatively large studs on the first member in the heel area, which may bear most of the athlete's weight when standing or walking, while finer studs may be more appropriate on the second member in the forefoot area, to improve the athlete's performance when running, when most of the athlete's weight would be on the forefoot area.

The second member may be shorter along a longitudinal direction of the footwear than the first member. A shorter second member allows for greater flexibility of the sole and a lower weight.

The second member may comprise at least one positioning hole and the first member may comprise at least one positioning stud which is fitted in a formfitting manner into said positioning hole. A positioning hole and a positioning stud improve the stability of the outsole construction and also ensures a proper alignment of the first and second member. Preferably, the positioning stud, and the corresponding positioning hole, is not circular in order to prevent a rotation of the second member when transverse torques act upon the second member. Furthermore, a positioning stud in the first member that is arranged through a positioning hole in the second member adds grip in the region of the second member such that the second member does not necessarily have to comprise a stud or ground engaging profile, allowing a further weight reduction.

The first member and/or the second member may contain weight-reducing perforations. A suitable choice of perforation profile allows a construction of the sole that is more lightweight yet that maintains a similar structural stability as an un-perforated counterpart. Normally, ribs are placed on the outside of a boot chassis for required stiffness. It is possible to achieve a similar stiffness by forming a perforation comprising holes arranged longitudinally against flex direction so as to form a rib-like structure between the rows of holes. By choosing a location of the holes around the thickest areas of the first and/or second member it is possible to achieve a maximum amount of weight reduction, while maintaining stability and good manufacturing properties. A weight reduction of the sole benefits an athlete in both greater wearing comfort and improved performance.

The first member may comprise a heel counter. A heel counter allows greater support of the athlete's foot in sports where such increased support is required. Moreover, by combining the heel counter with a portion of the outsole, the stability is even more increased.

The second member may comprise a spine fitted in a formfitting manner into a corresponding recess in the first member. The spine provides additional stability for the second member against forces transverse to the direction of the spine. The spine may also improve the look and design of an article of footwear.

The first member may be made from polyamide <NUM> and / or polyamide <NUM> and / or the second member may be made from thermoplastic polyurethane, polyurethane, or polyether block amide. Polyamide <NUM> and polyamide <NUM> provide a good rigidity, elastic, and shear properties while thermoplastic polyurethane, polyurethane, or polyether block amide are light-weight, flexible, and have good damping properties.

The second member may be attached to the first member in a non-detachable manner. For certain sports or activities, it may be desirable to have a maximum level of stability, which could be best achieved by a non-detachable connection of the second member to the first member.

The second member may be attached to the first member in a detachable manner. By allowing the second member to be detached from the first member, the outsole could be modified after purchase. A customer could choose, for instance, a second member that provides ideal grip for a particular sport and on a particular surface. The customer could then freely combine this second member with a first member that provides a preferred level of heel support for a customer's personal preference. Such a modification could be carried out by the customer himself, or by a service provider, for example in a store. The detachable connection could be provided by any suitable means, for example there may be a thread in the first member and a screw placed through the second member could be used to fix the second member to the first member. The screw could be integrally formed with the ground engaging profile, in particular with a stud.

The invention further concerns a method for producing an article of cleated footwear, comprising: (a) supplying an outsole plate, comprising (i) forming a rigid first member, extending substantially along the length of the outsole, and (ii) forming a rigid second member, wherein the first member and / or the second member comprise a ground-engaging profile; (b) supplying an upper; (c) attaching the upper to the first member; and (d) attaching the first member to the second member.

Step (c) attaching the upper to the first member is preferably performed before step (d) attaching the first member to the second member.

The first member and the second member may have a ground-engaging profile in which case both the first member and the second member provide grip and stability. Alternatively, just the second member may have a ground-engaging profile in which case the second member provides grip and the first member provides stability. Alternatively, just the first member may have a ground-engaging profile in which case the first member provides grip and stability, and the second member improves the stability in those regions where it is most required.

Attaching the upper to the first member may comprise: (a) lasting a first part of the upper around a first region of the first member; and (b) arranging at least a portion of the first part of the upper between the first member and the second member in at least a portion of the first region. In this case, step (c) attaching the upper to the first member is preferably performed before step (d) attaching the first member to the second member in order to simplify the step of attaching the upper to the first member.

The upper may be attached to the first member by sewing a second part of the upper to a sheet and attaching the sheet to a second region of the first member. For example, the upper could be sewn using a Strobel sewing machine. The sheet-like material could be made from ethyl vinyl acetate, polyurethane, the same material as the upper, or any other suitable material. It is also feasible that the upper is directly sewn to the first member.

This construction allows the overall weight of the article of footwear to be reduced as it is more lightweight than the configuration in the first region. It is also faster and easier to assemble the article of footwear in this second region than to perform the board lasting in the first region.

The method may comprise arranging the second member of the outsole plate to extend over at least a part of the second region and a part of the first region, such that the second member covers the transition point between the second region and the first region.

The method may further comprise: (a) arranging the second region in a heel region and/or a shank region of the article of cleated footwear; and / or (b) arranging the first region in a forefoot region of the article of cleated footwear.

The method may further comprise forming a cut-out region in the sheet. The inventors have found that it is possible to still provide a stable connection of the upper to the first member if the sheet comprises a cut-out region. A cut-out region is an area in the sheet where a hole is formed in the sheet or where the material of the sheet is thinner than in another region. Preferably the cut-out region is at the center of the sheet. A hole may be cut into the sheet before or after sewing the upper to the sheet. Alternatively, a hole could be formed in the sheet while the sheet is produced. Another alternative is that the material of the sheet it made thinner in part of the sheet by mechanical means such as grinding or by chemical means such as etching. The cut-out region reduces the weight of the article of footwear.

The sheet may be made from a synthetic material, leather, and / or a textile. The sheet may be from the same material as the upper. These materials are advantageous because they are durable and prevent the upper from tearing where it is sewn to the sheet and provide a comfortable level of cushioning.

Attaching the sheet to the first member may comprise using an adhesive and / or welding. An adhesive is a simple way of forming a strong and permanent bond. If the materials used allow welding, then welding may be a preferred method as it does not require the use of an additional adhesive, yet allows a strong bond to be formed.

The first member and/or the second member may be formed by injection-molding. Injection molding is a cost-effective and simple method of forming solid components, that are made from a meltable material, even with complex shapes in a reproducible manner.

The first member may comprise a first ground-engaging profile, which comprises at least one stud of a first type and/or the second member may comprise a second ground-engaging profile, which comprises at least one stud of a second type.

The second member may be formed to be shorter along a longitudinal direction of the outsole than the first member. A shorter second member allows for greater flexibility of the sole and a lower weight.

The method may further comprise forming at least one positioning hole in the second member and at least one positioning stud in the first member, wherein the positioning stud is fitted in a formfitting manner into the positioning hole, when the first member is attached to the second member. A positioning hole and a positioning stud improve the stability of the outsole construction and also ensures a proper alignment of the first and second member. Preferably, the positioning stud, and the corresponding positioning hole, is not circular in order to prevent a rotation of the second member when transverse torques act upon the second member. Furthermore, a positioning stud in the first member that is arranged through a positioning hole in the second member adds grip in the region of the second member such that the second member does not necessarily have to comprise a stud or ground engaging profile, allowing a further weight reduction.

The method may further comprise forming weight-reducing perforations in the first member and/or the second member. A suitable choice of perforation profile allows the construction of a sole that is more lightweight yet that maintains a similar structural stability as an un-perforated counterpart. Normally, ribs are placed on the outside of a boot chassis for required stiffness. It is possible to achieve a similar stiffness by forming a perforation comprising holes arranged longitudinally against flex direction so as to form a rib-like structure between the rows of holes. By choosing a location of the holes around the thickest areas of the first and/or second member it is possible to achieve a maximum amount of weight reduction, while maintaining stability and good manufacturing properties. A weight reduction of the sole benefits an athlete in both greater wearing comfort and improved performance.

The method may further comprise forming a heel counter in the first member. A heel counter allows greater support of the athlete's foot in sports where such increased support is required. Moreover, by combining the heel counter with a portion of the outsole, the stability is even more increased.

The method may further comprise forming a spine in the second member and forming a corresponding recess in the first member. The spine provides additional stability for the second member against forces transverse to the direction of the spine. The spine may also improve the look and design of an article of footwear.

Attaching the first member to the second member may form a non-detachable connection. For certain sports or activities, it may be desirable to have a maximum level of stability, which could be best achieved by a non-detachable connection of the second member to the first member.

Attaching the first member to the second member may form a detachable connection. By allowing the second member to be detached from the first member, the outsole could be modified after purchase. A customer could choose, for instance, a second member that provides ideal grip for a particular sport and on a particular surface. The customer could then freely combine this second member with a first member that provides a preferred level of heel support for a customer's personal preference. Such a modification could be carried out by the customer himself, or by a service provider, for example in a store. The detachable connection could be provided by any suitable means, for example there may be a thread in the first member and a screw placed through the second member could be used to fix the second member to the first member. The screw could be integrally formed with the ground engaging profile, in particular with a stud.

In the following, the invention will be described in more detail with reference to the figures:.

In the following only some exemplary embodiments of the invention are described in detail. These exemplary embodiments can be modified in a number of ways and combined with each other whenever compatible and certain features may be omitted in so far as they appear dispensable. The scope of the invention is determined only by the independent claims and is not limited by any of the exemplary embodiments.

<FIG> shows a preferred embodiment of a rigid first member <NUM>, also known as chassis, and a rigid second member <NUM>, also known as skin, according to the present invention.

The first member <NUM> is rigid and extends substantially along the length of the outsole of the article of footwear. Thus, the length of the first member <NUM> is preferably at least <NUM>% of the length of the outsole of the article of footwear, more preferably at least <NUM>%, most preferably <NUM>%, wherein the length is measured along a longitudinal direction of the outsole of the article of footwear. The first member <NUM> therefore serves as the primary element for providing a structure to the outsole. Unlike an insole or lasting board, the first member <NUM> may have a first ground-engaging profile. The first member <NUM> therefore may have both the structural function of an insole or lasting board in that it provides rigidity to the sole, but the first member <NUM> may further provide some of the grip properties of the outsole. The use of a first member <NUM> therefore allows a simpler and more lightweight construction than a conventional insole board combined with a second element with an outsole profile. With this construction, an insole board is not required, which simplifies the construction of the sole, saving processing time and costs and leads to an article of footwear with a lower total weight without sacrificing mechanical performance. The inventors have discovered that a weight reduction is possible due to this improved construction.

The first member <NUM> and / or the second member <NUM> could be formed from injection molding or any another suitable technique. The first member <NUM> could be made from polyamide <NUM> and / or polyamide <NUM>, which provide a good rigidity, elastic, and shear properties. The second member <NUM> could be made from thermoplastic polyurethane, polyurethane, or polyether block amide. Thermoplastic polyurethane, polyurethane, or polyether block amide are light-weight, flexible, and have good damping properties. The first and second member <NUM> could also be made from other materials and they could be made from the same material or from different materials.

The second member <NUM> preferably has a longitudinal length of at least <NUM>% of the length of the first member, more preferably <NUM>%. It is to be understood that the second member <NUM> is not merely a stud. A function of the second member <NUM> is to provide an ideal level of grip for the athlete whilst maintaining a low weight and good wearing comfort. The second member <NUM> can be constructed to suit any particular sport or surface of sports grounds. Thus, during production, the same type of first member can be used for articles of footwear of different type (e.g. soccer shoe, rugby shoe, etc.), while only the second member <NUM> is varied. This is contrary to conventional cleated footwear, for which, starting from a particular shoe, the entire soleplate has to be re-designed and manufactured even for a similar shoe that is used on a different surface (e.g. hard, soft, artificial turf), a different sport, or by a different type of athlete (e.g. beginner, ambitious amateur, professional, etc.).

Another advantage of this construction lies in the modular nature of the sole plate which simplifies the assembly of said soleplate by the manufacturer, for instance at a factory or at a store. Each piece, the first member <NUM> and the second member <NUM>, could be made from different materials and undergo different treatment to achieve particular mechanical or design properties. It is also feasible that a customer can easily and flexibly modify the article of cleated footwear after purchase. Thus, a customer does not have to purchase an entirely new shoe for a new activity, resulting in a favorable environmental impact.

In the exemplary embodiment of <FIG>, the first member <NUM> contains weight-reducing perforations <NUM> in both the forefoot region <NUM> and the heel region <NUM>. The second member <NUM> also contains weight-reducing perforations <NUM> which are also formed on the studs <NUM>. A suitable choice of perforation profile allows the construction of the sole that is more lightweight yet that maintains a similar structural stability as an un-perforated counterpart. Normally, ribs are placed on the outside of a boot chassis for required stiffness. It is possible to achieve a similar stiffness by forming a perforation comprising holes arranged longitudinally against flex direction so as to form a rib-like structure between the rows of holes. By choosing a location of the holes around the thickest areas of the first and/or second member it is possible to achieve a maximum amount of weight reduction, while maintaining stability and good manufacturing properties. A weight reduction of the sole benefits an athlete in both greater wearing comfort and improved performance.

The first member <NUM> contains a number of studs of a first type <NUM> in the heel region <NUM> to provide basic grip for the athlete. A recess <NUM> is formed in the first member <NUM> to accept the spine <NUM> of the second member <NUM> to provide further stability for the attachment of the spine on the first member <NUM> against forces transverse to the direction of the spine <NUM>.

In the exemplary embodiment of <FIG>, a positioning stud <NUM> is present to allow accurate and stable alignment of the second member <NUM> with respect to the first member <NUM> by means of a positioning hole <NUM> formed in the second member <NUM>. The positioning hole <NUM> and the positioning stud <NUM> can be chosen to have a particular size and shape depending on the needed stability. There may be more than one positioning stud and corresponding positioning hole. Preferably, the positioning stud <NUM>, and the corresponding positioning hole <NUM>, is not circular in order to prevent a rotation of the second member <NUM> when transverse torques act upon the second member <NUM>. Furthermore, a positioning stud <NUM> in the first member <NUM> that is arranged through a positioning hole <NUM> in the second member <NUM> adds grip in the region of the second member <NUM> such that the second member <NUM> does not necessarily have to comprise a stud or ground engaging profile, allowing a further weight reduction.

The studs <NUM> on the second member <NUM> are located close to the forefoot region <NUM> of the first member <NUM>. The number and shape of the studs <NUM> can be chosen for a specific type of surface of the sports ground and/or a particular sport.

In this preferred embodiment, the studs <NUM> on the second member <NUM> are of a different shape than the studs <NUM> on the first member <NUM>. Here, the studs <NUM> on the second member <NUM> are v-shaped to enable optimal performance for the athlete during running, when most of the athlete weight is on the forefoot region. The studs <NUM> on the first member are of a circular cross-section, to allow the athlete to turn quickly when walking or standing, when most of the athlete's weight on the heel region.

The second member <NUM> is shorter along a longitudinal direction than the first member <NUM> in this embodiment. A shorter second member <NUM> allows for greater flexibility of the sole and a lower weight.

The outsole plate is formed by attaching the second member <NUM> to the first member <NUM>, for example by using an adhesive, while ensuring the alignment of the positioning hole <NUM> with the positioning stud <NUM> and of the spine <NUM> with the recess <NUM>.

In an alternative embodiment, the attachment could be facilitated by using screws in order to provide a detachable connection. In another alternative embodiment, the first member could include forefoot studs and the second member could have fewer studs to make the board lasting area shorter.

Preferably, a first part of the upper 30a is lasted around a first region <NUM> of the first member <NUM> and the second member <NUM> is attached to the first member <NUM> such that at least a portion of the first part of the upper 30a is arranged between the first member <NUM> and the second member <NUM> in at least a portion of the first region <NUM>. This is described in more detail with reference to <FIG> below.

<FIG> shows another example of an outsole plate according to the present invention. The outsole plate of <FIG> does not have weight reducing perforations. <FIG> schematically shows an arrangement of a first member <NUM> and a second member <NUM> in an exploded view of an exemplary embodiment. The second member contains a positioning hole <NUM> which can be brought in formfitting conjunction with the positioning stud <NUM> of the first member <NUM> to provide good stability. The second member <NUM> also contains several studs <NUM> for providing ideal grip for the athlete, depending on the surface of the sports ground and the sport. The first member contains several studs <NUM> for basic grip at the heel and a heel counter <NUM> for supporting the athlete's heel.

<FIG> show an exemplary arrangement of an upper <NUM> and a first member <NUM>, forming part of an article of cleated footwear according to the present invention. The second member <NUM> has been omitted for clarity.

<FIG> shows an upper <NUM> comprising a second part 30b and a first part 30a. The second part 30b is sewn to a sheet-like material <NUM>. The stitching <NUM> is preferably located at a rim of the upper. The sheet-like material is substantially similar to a sheet and is also referred to as sheet <NUM>. The sheet <NUM> could be made from ethyl vinyl acetate, polyurethane, a textile material (e.g. a woven material), the same material as the upper, or any other suitable material. The purpose of the sheet is to provide some cushioning to the wearer of the article of footwear and a tear-resistant means for attaching the second part 30b of the upper <NUM> to the first member <NUM>. The sewing may, for example, be performed using a Strobel sewing machine. The first part 30a of the upper is open and comprises ears with an outside surface 32b and an inner surface 32a. The ears <NUM> are functional for facilitating the lasting of the upper as explained with reference to <FIG> below.

<FIG> shows an alternative version of <FIG>, in which a cut-out region <NUM> is formed in the sheet <NUM>. The inventors have found that it is possible to still provide a stable connection of the upper <NUM> to the first member <NUM> if the sheet comprises a cut-out region <NUM>. A cut-out region <NUM> is an area in the sheet where a hole is formed in the sheet or where the material of the sheet is thinner than in another region. Preferably the cut-out region <NUM> is at the center of the sheet. A hole may be cut into the sheet before or after sewing the upper to the sheet. Alternatively, a hole could be formed in the sheet while the sheet is produced. Another alternative is that the material of the sheet it made thinner in part of the sheet by mechanical means such as grinding or by chemical means such as etching. The cut-out region <NUM> reduces the weight of the article of footwear.

For brevity, <FIG> comprise only the sheet <NUM> shown in <FIG>, however, the procedure for the sheet <NUM> with the cut-out region <NUM> shown in <FIG> is analogous.

<FIG> shows how the upper <NUM> can be lasted on a last <NUM>. The last comprises a rim <NUM> to which the ears <NUM> can be temporarily attached to facilitate consolidation during lasting.

<FIG> shows how a first part 30a of the upper is board-lasted around a first region <NUM> of the first member <NUM>. The board-lasting involves attaching the inside 32a of the ears of the upper to the underside of the first member <NUM>. The outside 32b of the ears is still visible in <FIG>. This attachment can be facilitated for example by gluing with a suitable adhesive. This arrangement allows to directly last the upper onto the first member in the first region. This makes an insole board redundant and reduces the number of components and the weight of the article of footwear while maintaining good mechanical stability.

<FIG> also shows how the second part 30b of the upper is attached to a second region <NUM> of a first member <NUM> by means of attaching the sheet <NUM> to the first member <NUM>, for example by use of an adhesive or by welding. This construction allows the overall weight of the article of footwear to be reduced as it is more lightweight than the configuration in the first region <NUM>. It is also faster and easier to assemble the article of footwear in this second region <NUM> than to perform the board lasting in the first region <NUM>.

In a further method step (not shown), a second member <NUM> is attached to the first member. The second member is attached in such a way as to "sandwich" the ears <NUM> in the first region <NUM> between the first and the second member. The alignment of the first member <NUM> and the second member <NUM> is preferably facilitated by an alignment stud <NUM> in the first member and a corresponding alignment hole <NUM> in the second member. The second member <NUM> is preferably attached to the first member <NUM> by an adhesive to facilitate a strong permanent bond.

However, it is also possible to attach the second member <NUM> to the first member <NUM> in a detachable manner, e.g. using a screw in the second member and a corresponding thread in the first member <NUM>.

Regardless of whether the second member <NUM> is attached to the first member <NUM> in a detachable or permanent manner, the second member <NUM> is preferably attached to the first member such that the second member covers at least part of both regions <NUM> and <NUM>, that is, the second member covers the transition point between the board-lasted region <NUM> and the sewn/glued/welded region <NUM>. It is beneficial if this transition point is covered by the first member because the upper could tear at this point or detach from the first and/or second member. The transition point must be carefully selected because if the board lasting is cut off too early, that is if the board lasted area <NUM> is too short, the interface between the skin and the chassis won't be flush at the transition point which is required for the mechanical stability, especially of cleated footwear. If, however, the board lasted area <NUM> is too long, the weight of the article of footwear is increased unnecessarily.

Claim 1:
An article of cleated footwear comprising:
a) an outsole plate comprising:
(i) a rigid first member (<NUM>), extending substantially along the length of the outsole, and
(ii) a rigid second member (<NUM>),
(iii) wherein the second member (<NUM>) is attached to the first member (<NUM>),
(iv) wherein the second member (<NUM>) has a ground-engaging profile (<NUM>, <NUM>), and
(v) wherein the second member (<NUM>) is shorter along a longitudinal direction of the footwear than the first member (<NUM>);
b) an upper (<NUM>) attached to the first member (<NUM>), wherein:
(aa) a first part of the upper (30a) is lasted around a first region (<NUM>) of the first member (<NUM>); and
(bb) the second member (<NUM>) is attached to the first member (<NUM>) such that
at least a portion of the first part of the upper (30a) is arranged between the first member (<NUM>) and the second member (<NUM>) in at least a portion of the first region (<NUM>).