SOLE STRUCTURE FOR ARTICLE OF FOOTWEAR

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S. C. § 119(e) to U.S. Provisional Application No. 63/679,784, filed on Aug. 6, 2024. The disclosure of this prior application is considered part of the disclosure of this application and is hereby incorporated by reference in its entirety.

FIELD

The present disclosure relates generally to an article of footwear, and more particularly to a sole structure for an article of footwear

BACKGROUND

This section provides background information related to the present disclosure and is not necessarily prior art.

Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support a foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate to a bottom surface of the foot, attaches to the sole structure.

Sole structures generally include a layered arrangement extending between a ground surface and the upper and include an outsole. The outsole may include a sole plate formed of a rigid or semi-rigid material that provides rigidity and energy distribution across the sole structure. The sole plate may be provided with one or more ground-engaging members for engagement with a ground surface.

While known sole structures have proven acceptable for their intended purposes, a continuous need for improvement in the relevant art remains. For example, a need exists for an outsole that provides improved traction with the ground surface when forces having varying magnitude and direction are applied from the midsole or the upper to the outsole. A need also exists for an article of footwear having improved overall comfort and fit while providing such improved traction.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected configurations and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a bottom perspective view showing an article of footwear incorporating a sole structure according to the principles of the present disclosure;

FIG. 2 is a top perspective view of the article of footwear of FIG. 1;

FIG. 3 is a medial side elevation view of the article of footwear of FIG. 1;

FIG. 4 is a lateral side elevation view of the article of footwear of FIG. 1;

FIG. 5 is an exploded bottom perspective view of the article of footwear of FIG. 1;

FIG. 6 is an exploded top perspective view of the article of footwear of FIG. 1;

FIGS. 7A and 7B are bottom plan views of the article of footwear of FIG. 1;

FIG. 8 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 8-8 of FIG. 7B;

FIG. 9 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 9-9 of FIG. 7B;

FIG. 10 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 10-10 of FIG. 7B;

FIG. 11 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 11-11 of FIG. 7B;

FIG. 12 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 12-12 of FIG. 7B;

FIG. 13 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 13-13 of FIG. 7B;

FIG. 14 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 14-14 of FIG. 7B;

FIG. 15 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 15-15 of FIG. 7B;

FIG. 16 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 16-16 of FIG. 7B;

FIG. 17 is a bottom perspective view showing an article of footwear incorporating a sole structure according to the principles of the present disclosure;

FIG. 18 is a top perspective view of the article of footwear of FIG. 17;

FIG. 19 is a medial side elevation view of the article of footwear of FIG. 17;

FIG. 20 is a lateral side elevation view of the article of footwear of FIG. 17;

FIG. 21 is an exploded bottom perspective view of the article of footwear of FIG. 17;

FIG. 22 is an exploded top perspective view of the article of footwear of FIG. 17;

FIGS. 23A and 23B are bottom plan views of the article of footwear of FIG. 17;

FIG. 24 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 24-24 of FIG. 23;

FIG. 25 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 25-25 of FIG. 23;

FIG. 26 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 26-26 of FIG. 23;

FIG. 27 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 27-27 of FIG. 23;

FIG. 28 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 28-28 of FIG. 23;

FIG. 29 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 29-29 of FIG. 23;

FIG. 30 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 30-30 of FIG. 23;

FIG. 31 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 31-31 of FIG. 23;

FIG. 32 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 32-32 of FIG. 23;

FIG. 33 is a cross-sectional view of the article of footwear of FIG. 1, taken along Line 33-33 of FIG. 23;

FIG. 34 is a top perspective view of a traction pad according to another example of the disclosure; and FIG. 35 is a bottom perspective view of the traction pad of FIG. 34.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope of those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

An aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes at least one of a plate shell or a plate chassis extending from a forefoot region of the sole structure to a heel region of the sole structure and defining a peripheral edge of the sole structure. The sole structure further includes a plurality of first traction elements extending from the at least one of the plate shell or the plate chassis and arranged in an annular pattern in a forefoot region of the sole structure. A first rib extends along the peripheral edge of the sole structure from a first end adjacent to the forefoot region of the sole structure to a second end adjacent to the heel region of the sole structure, and a traction pad attached to the at least one of the plate shell or the plate chassis and surrounded by the plurality of the first traction elements.

This aspect of the disclosure may include one or more of the following optional features. In some examples, the first rib includes a first traction element disposed at the first end of the first rib and a second traction element disposed at the second end of the first rib. Optionally, the first traction element is a directional traction element having a leading end facing the second end of the first rib and the second traction element is a directional traction element having a leading end facing the first end of the first rib.

In some implementations, the first rib extends along a medial side of the sole structure and at least partially defines a portion of the peripheral edge. In some examples, the first rib extends along an arcuate path from the first end to the second end and defines a concave ball receiving zone a long a medial side of the sole structure. In some configurations, the first rib includes a concave first sidewall facing a medial side of the sole structure and a convex second sidewall facing a lateral side of the sole structure.

In some examples, the sole structure further includes a second rib extending between the first rib and a lateral side of the sole structure from a third end adjacent to the forefoot region of the sole structure to a fourth end adjacent to the heel region of the sole structure. In some configurations, the first traction elements are elongate traction elements arranged in a directional annular pattern in the forefoot region. In some implementations, the traction pad includes a resilient material having a lower durometer than each of the at least one of the plate shell or the plate chassis.

Another aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes at least one of a plate shell or a plate chassis extending from a forefoot region of the sole structure to a heel region of the sole structure and defining a peripheral edge of the sole structure. The sole structure further includes a plurality of first traction elements extending from the at least one of the plate shell or the plate chassis and arranged in an annular pattern in a forefoot region of the sole structure. The sole structure further includes a first rib extending along the peripheral edge of the sole structure from a first end adjacent to the forefoot region of the sole structure to a second end adjacent to the heel region of the sole structure. The sole structure further includes a second rib extending between the first rib and a lateral side of the sole structure from a third end adjacent to the forefoot region of the sole structure to a fourth end adjacent to the heel region of the sole structure.

This aspect of the disclosure may include one or more of the following optional features. In some examples, the first rib includes a first traction element disposed at the first end of the first rib and a second traction element disposed at the second end of the first rib. In some implementations, the first traction element is a directional traction element having a leading end facing the second end of the first rib and the second traction element is a directional traction element having a leading end facing the first end of the first rib.

In some examples, the first rib extends along a medial side of the sole structure and at least partially defines a portion of the peripheral edge. Optionally, the first rib extends along an arcuate path from the first end to the second end and defines a concave ball receiving zone along a medial side of the sole structure. In some configurations, the first rib includes a concave first sidewall facing a medial side of the sole structure and a convex second sidewall facing a lateral side of the sole structure.

In some configurations, the first traction elements are elongate traction elements arranged in a directional annular pattern in the forefoot region. In some examples, the sole structure further comprises a traction pad attached to the at least one of the plate shell or the plate chassis and surrounded by the plurality of the first traction elements. In some implementations, the traction pad includes a resilient material having a lower durometer than each of the at least one of the plate shell or the plate chassis.

Another aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes at least one of a plate shell or a plate chassis extending from a forefoot region of the sole structure to a heel region of the sole structure and defining a peripheral edge of the sole structure. The sole structure further includes a plurality of first traction elements extending from the at least one of the plate shell or the plate chassis and arranged in an annular pattern in a forefoot region of the sole structure. The sole structure further includes a first rib defining a ball receiving zone extending along the peripheral edge of the sole structure from a first end adjacent to the forefoot region of the sole structure to a second end adjacent to the heel region of the sole structure. Optionally, the first rib includes a first traction element disposed at the first end of the first rib and a second traction element disposed at the second end of the first rib.

Another aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes a plate shell extending from a forefoot region of the sole structure to a heel region of the sole structure and having a constant thickness extending between an upper side and an opposite a bottom side. The sole structure further includes a plate frame disposed adjacent to the bottom side of the plate shell and including (i) a first arcuate spine extending from a first spine end in the forefoot region to a second spine end in the heel region and (ii) a first annular spine extending from the first spine end in the forefoot region.

This aspect of the disclosure may include one or more of the following optional features. In some examples, the sole structure includes a traction assembly including a first member including a first portion received between the plate frame and the bottom side of the plate shell and a second portion exposed along the bottom side of the plate shell. Optionally, the traction assembly further comprises a second member formed separately from the first member and extending along an arcuate path adjacent to a medial side of the plate shell.

In some examples, the traction assembly includes a second arcuate spine received between the first arcuate spine of the plate frame and the bottom side of the plate shell. Optionally, the traction assembly includes a plurality of elongate traction ribs extending through the plate frame from the second arcuate spine. In some implementations, the traction assembly includes (i) a second annular spine received between the first annular spine of the plate frame and the bottom side of the plate shell and (ii) a traction pad attached to the second annular spine and exposed within the first annular spine.

In some configurations, the sole structure includes a plate chassis extending from a first end in the forefoot region of the sole structure to a second end in a heel region of the sole structure, the plate chassis including a top side defining a footbed and a lower side formed on an opposite side from the top side and configured to mate with the upper side of the plate shell.

Another aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes a plate shell extending from a forefoot region of the sole structure to a heel region of the sole structure and formed of a film material having a constant thickness, a plate frame disposed adjacent to a bottom side of the plate shell and including (i) a first arcuate spine extending from a first spine end in the forefoot region to a second spine end in the heel region and (ii) a first annular spine extending from the first spine end in the forefoot region.

This aspect of the disclosure may include one or more of the following optional features. In some examples, the sole structure further includes a traction assembly including a first member including a first portion received between the plate frame and the bottom side of the plate shell and a second portion exposed along the bottom side of the plate shell. Optionally, the traction assembly further comprises a second member formed separately from the first member and extending along an arcuate path adjacent to a medial side of the plate shell.

In some implementations, the traction assembly includes a second arcuate spine received between the first arcuate spine of the plate frame and the bottom side of the plate shell. Optionally, the traction assembly includes a plurality of elongate traction ribs extending through the plate frame from the second arcuate spine. In some examples, the traction assembly includes (i) a second annular spine received between the first annular spine of the plate frame and the bottom side of the plate shell and (ii) a traction pad attached to the second annular spine and exposed within the first annular spine.

In some implementations, the sole structure includes a plate chassis extending from a first end in the forefoot region of the sole structure to a second end in a heel region of the sole structure, the plate chassis including a top side defining a footbed and a lower side formed on an opposite side from the top side and configured to mate with an upper side of the plate shell.

Another aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes a plate shell extending from a forefoot region of the sole structure to a heel region of the sole structure and formed of a film material having a constant thickness. The sole structure further includes a traction assembly disposed adjacent to a bottom side of the plate shell and including a first member having a first arcuate spine extending from the forefoot region to the heel region along a first arcuate path and a second member formed separate from the first member and extending through a mid-foot region along a second arcuate path.

In some implementations, the plate shell includes a peripheral edge defining a first recess extending along a medial side of the plate shell from a first end adjacent to the forefoot region to a second end adjacent to the heel region and an elongate rib extending continuously along a portion of the peripheral edge defining the first recess. In some examples, the elongate rib includes a first traction element at a first end of the elongate rib and a second traction element at an opposite second end of the elongate rib. In some configurations, the second member of the traction assembly is attached to the elongate rib between the first end and the second end.

In some configurations, the traction assembly includes an annular spine extending from the first arcuate spine in the forefoot region and a traction pad attached to and at least partially surrounded by the annular spine. In some configurations, the sole structure further includes a plate frame attached to the bottom side of the plate shell, at least a portion of the traction assembly received between the bottom side of the plate shell and the plate frame.

Referring to FIGS. 1-7B, an article of footwear 10 includes an upper 100 and sole structure 200. The article of footwear 10 may be divided into one or more regions. The regions may include a forefoot region 12, a mid-foot region 14, and a heel region 16. The forefoot region 12 may be subdivided into a toe portion 12_T corresponding with phalanges, and a ball portion 12_B associated with metatarsal bones of a foot. The mid-foot region 14 may correspond with an arch area of the foot, and the heel region 16 may correspond with rear portions of the foot, including a calcaneus bone. The footwear 10 may further include an anterior end 18 associated with a forward-most point of the forefoot region 12, and a posterior end 20 corresponding to a rearward-most point of the heel region 16. As shown in FIG. 7A, a longitudinal axis A₁₀ of the footwear 10 extends along a length of the footwear 10 from the anterior end 18 to the posterior end 20, and generally divides the footwear 10 into a medial side 22 and a lateral side 24. Accordingly, the medial side 22 and the lateral side 24 respectively correspond with opposite sides of the footwear 10 and extend through the regions 12, 14, 16.

The upper 100 includes interior surfaces that define an interior void 102 configured to receive and secure a foot for support on sole structure 200. The upper 100 may be formed from one or more materials that are stitched or adhesively bonded together to form the interior void 102. Suitable materials of the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort.

In some examples, the upper 100 includes a strobel 104 having a bottom surface opposing the sole structure 200 and an opposing top surface defining a footbed of the interior void 102. Stitching or adhesives may secure the strobel 104 to the upper 100. The footbed may be contoured to conform to a profile of the bottom surface (e.g., plantar) of the foot. Optionally, the upper 100 may also incorporate additional layers such as an insole or sockliner (not shown) that may be disposed upon the strobel and reside within the interior void 102 of the upper 100 to receive a plantar surface of the foot to enhance the comfort of the article of footwear 10. An ankle opening in the heel region 16 may provide access to the interior void 102. For example, the ankle opening may receive a foot to secure the foot within the void 102 and to facilitate entry and removal of the foot from and to the interior void 102.

Referring to FIGS. 1-6, the sole structure 200 includes a plate shell 202 disposed on a bottom side of the strobel 104 and a plate chassis 204 disposed within the upper 100 and on an opposite side of the strobel 104 from the plate shell 202. Thus, when the sole structure 200 is assembled with the upper 100, the strobel 104 of the upper 100 is interposed between the plate chassis 204 and the plate shell 202. The plate shell 202 forms an exterior portion of the article of footwear 10 and defines at least a portion of a ground-engaging surface 26 of the sole structure 200. The sole structure 200 further includes a plate frame 206 attached to the plate shell 202 on an opposite side from the plate chassis 204. The plate frame 206 defines a second portion of the ground-engaging surface 26 of the sole structure 200. The sole structure 200 includes a traction assembly 208 disposed adjacent to the plate shell 202 and defining a third portion of the ground-engaging surface 26. At least a portion of the traction assembly 208 may be received or captured between the plate shell 202 and the plate frame 206. Optionally, the sole structure 200 includes a plurality of traction elements 210a-210k attached to at least one of the plate shell 202 and the plate frame 206.

Referring still to FIGS. 1-6, the plate shell 202 extends the full length of the article of footwear 10 from a first end 212 at the anterior end 18 of the article of footwear 10 to a second end 214 at the posterior end 20 of the article of footwear. The plate shell 202 includes an upper side 216 that is configured to face the strobel 104 of the upper 100 when the sole structure 200 is assembled with the upper 100. The plate shell 202 includes a bottom side 218 formed on an opposite side from the upper side 216, whereby a distance from the upper side 216 to the bottom side 218 defines a thickness T₂₀₂ (FIG. 10) of the plate shell 202. The bottom side 218 of the plate shell 202 defines a first portion of the ground-engaging surface 26 of the article of footwear 10 when then sole structure 200 is assembled with the upper 100.

A peripheral edge 220 extends between the upper side 216 and the bottom side 218 and defines an outer peripheral profile of the plate shell 202. The peripheral edge 220 defines convex curvatures along each of the first end 212 and the second end 214, whereby a radius of the curvature at the first end 212 corresponds to a ball of the foot and a radius of the curvature at the second end 214 corresponds to a heel of the foot and is generally smaller than the radius at the first end. The peripheral edge 220 may include a first continuous concave curvature extending along the lateral side 24 between the first end 212 and the second end 214. The peripheral edge 220 defines a pair of recesses 222, 224 along the medial side 22 between the first end 212 of the plate shell 202 and the second end 214 of the plate shell 202. Particularly, the peripheral edge 220 includes a mid-foot recess 222 defined by a concave portion of the peripheral edge 220 extending continuously from a first end adjacent to the forefoot region 12 to a second end adjacent to the heel region 16. The peripheral edge 220 further includes a forefoot recess 224 defined by a concave portion of the peripheral edge 220 extending from a first end in the ball portion 12_B to a second end in the toe portion 12_T of the forefoot region 12. An apex of the forefoot recess 224 is aligned along a metatarsophalangeal (MTP) axis A_MTP of the sole structure 200 (FIG. 7A). Thus, the forefoot recess 224 provides a relief region along the medial side of the plate chassis 204 along which the toe portion 12_T can flex relative to the ball portion 12_B.

With continued reference to FIG. 3, the peripheral edge 220 defines a pair of wings 226, 228 along the medial side 22 of the plate shell 202 at opposite ends of the mid-foot recess 222. Particularly, the peripheral edge includes a forefoot wing 226 disposed between the forefoot recess 224 and the mid-foot recess 222 in the forefoot region 12. As shown in FIG. 3, the forefoot wing 226 is positioned between the ball portion 12_B and the mid-foot region 14. The peripheral edge 220 further includes a heel wing 228 disposed between the mid-foot region 14 and the heel region 16 at a posterior end of the mid-foot recess 222. The wings 226, 228 are defined by convex portions of the peripheral edge 220 at opposite ends of the mid-foot recess 222 and are configured to protrude in a direction away from the upper side 216 of the plate shell 202. Thus, each of the wings 226, 228 provides a convex projection extending from the sole structure 200 along a medial side of the upper 100 to provide lateral support in the forefoot region 12 and the heel region 16.

The bottom side 218 of the plate shell 202 defines various features configured to interface with and/or attach to the plate frame 206, the traction assembly 208, and/or the traction elements 210a-210k. As discussed above, the plate shell 202 is formed as a film structure having a constant thickness T₂₀₂. In the illustrated example, the plate shell 202 has a substantially constant thickness T₂₀₂ ranging from 0.1 mm to 1 mm, and more preferably from 0.3 mm to 0.5 mm. Accordingly, features formed on the bottom side 218 of the plate shell 202 correspond to complementary features on the opposite upper side 216 (e.g., a raised feature on the bottom side 218 results in a complementary recessed feature on the upper side 216). For the sake of this description, it should be understood that geometries of the plate shell 202 are described relative to the bottom side 218 and that the plate shell 202 includes complementary features formed in the upper side 216.

Referring to FIG. 5, the bottom side 218 of the plate shell 202 includes a plurality of protrusions or frame attachment bosses 230 configured to mate or engage with corresponding features of the plate frame 206. Each of the frame attachment bosses 230 is defined by an elongate protrusion formed along the bottom side 218. The bottom side 218 includes a first plurality of the frame attachment bosses 230 arranged in series in an annular pattern in the forefoot region 12, which are configured to mate to corresponding recesses formed in the traction assembly 208 when the plate frame 206 and the traction assembly 208 are attached to the bottom side 218 of the plate shell 202. The bottom side 218 further includes a pair of frame attachment bosses 230 arranged along the lateral side 24 at opposite ends of the mid-foot region 14, which mate with corresponding ribs of the plate frame 206.

Referring still to FIG. 5, the heel region of the plate shell 202 includes an elongate heel frame attachment rib 232 configured for attaching a second frame member 302 of the plate frame 206 in the heel region 16. As shown, the heel frame attachment rib 232 extends along an arcuate path from a first end 234 on the medial side 22 of the plate shell 202 to a second end 236 on the lateral side 24 of the plate shell 202. The curvature of the heel frame attachment rib 232 along the path from the first end 234 to the second end 236 generally corresponds to the convex curvature of the peripheral edge 220 along the second end 214 of the plate shell 202. Thus, an anterior-facing side of the heel frame attachment rib 232 is concave and a posterior-facing side of the heel frame attachment rib 232 is convex.

With continued reference to FIG. 5, the plate shell 202 includes an intermediate frame attachment rib 238 extending along an intermediate portion (i.e., between the medial and lateral sides 22, 24) of the bottom side 218. The intermediate frame attachment rib 238 is defined by the cooperation of a pair of sidewalls 240, 242 that each extend from the bottom side 218 of the plate shell 202 and converge with each other at a distal edge 243 (FIGS. 13 and 14). Thus, a width of the intermediate frame attachment rib 238 (i.e., the distance measured across the sidewalls 240, 242) tapers along a direction from the bottom side 218 of the plate shell 202 to the distal edge 243 of the intermediate frame attachment rib 238. The intermediate frame attachment rib 238 and each of the sidewalls 240, 242 extend continuously along an arcuate path from an anterior end 244 adjacent to the forefoot region 12 to a posterior end 246 adjacent to the heel region 16. Thus, the first sidewall 240 that faces the medial side 22 of the sole structure 200 defines a concave side of the intermediate frame attachment rib 238 while the second sidewall 242 that faces the lateral side 24 of the sole structure 200 defines a convex side of the intermediate frame attachment rib 238.

With continued reference to FIG. 5, the plate shell 202 includes a medial rib 248 extending along a portion of the peripheral edge 220 defining the mid-foot recess 222 on the medial side 22 of the plate shell 202. The medial rib 248 is defined by the cooperation of a pair of sidewalls 250, 252 that each extend from the bottom side 218 of the plate shell 202 and converge with each other at a distal end 254 (FIG. 13). Thus, a width of the medial rib 248 (i.e., the distance measured across the sidewalls 240, 242) tapers along a direction from the bottom side 218 of the plate shell 202 to the distal end 254 of the medial rib 248. As shown in FIG. 13, the distal end 254 of the medial rib 248 may be blunted to define an attachment surface for securing the traction assembly 208 to the plate shell 202. The medial rib 248 and each of the sidewalls 250, 252 extends continuously along an arcuate path from an anterior end 256 adjacent to the forefoot region 12 to a posterior end 258 adjacent to the heel region 16. Thus, the first sidewall 250 that faces the medial side 22 of the sole structure 200 defines a concave side of the medial rib 248 while the second sidewall 252 that faces the lateral side 24 of the sole structure 200 defines a convex side of the medial rib 248. As best shown in FIG. 7A, the first sidewall 250 and the second sidewall 252 also converge with each other at each of the anterior end 256 of the medial rib 248 and the posterior end 258 of the medial rib 248 such that each end 256, 258 of the medial rib 248 has a tapered edge. Forming the anterior end 256 and posterior end 258 with respective tapers may allow the ends 256, 258 to “knife” through a corresponding ground surface when the sole structure 200 is rotated about the mid-foot region 14, such as during an opposite-leg kicking movement.

As shown in FIGS. 5 and 7A, the medial rib 248 includes a pair of traction element bases 259a, 259b respectively formed at opposite ends of the medial rib 248. Particularly, the medial rib 248 includes a first traction element base 259a disposed at the anterior end 256 of the medial rib 248 and a second traction element base 259b disposed at the posterior end 258 of the medial rib 248. As described in greater detail below, each of the traction element bases 259a, 259b is configured for attaching a corresponding traction element tip 422 to define one of the traction elements 210a, 210b of the sole structure 200.

Generally, when assembled with the traction element tips 422, the traction element bases 259a, 259b of the medial rib 248 define directional traction elements 210a, 210b having a longitudinal axis extending along a direction from a leading end 416 to an opposite trailing end 418. As shown in FIG. 5, the traction element bases 259a, 259b are configured such that the longitudinal axes of the traction elements 210a, 210b are aligned with a longitudinal axis of the medial rib 248. In other words, the lengths of the traction elements 210a, 210b and the corresponding traction element bases 259a, 259b extend along the same arcuate path as the medial rib 248. The traction element bases 259a, 259b are oriented in opposite directions at each of the anterior end 256 and the posterior end 258 such that the respective trailing ends 418 face the corresponding ends 244, 246. Thus, the leading end 416 of the traction element 210a associated with the first traction element base 259a faces away from the anterior end 256 (i.e., toward the posterior end 258) and the leading end 416 of the traction element 210b associated with the second traction element base 259b faces away from the posterior end 258 (i.e., towards the anterior end 256).

Referring again to FIGS. 5 and 6, the plate chassis 204 is configured to mate with the upper side 216 of the plate shell 202, whereby the strobel 104 of the upper 100 is captured between the plate chassis 204 and the plate shell 202. The plate chassis 204 is a full-length plate chassis 204 that extends from a first end 260 at the anterior end 18 of the article of footwear 10 to a second end 262 at the posterior end 20 of the article of footwear 10. The plate chassis 204 includes a top side 264 and a lower side 266 formed on an opposite side from the top side 264. A distance from the top side 264 to the lower side 266 defines a thickness of the plate chassis 204. Unlike the plate shell 202, which is formed as a film member having a constant thickness T₂₀₂, the plate chassis 204 may be a molded component having a variable thickness and various reinforcing elements, such as integrated ribs and lattice structures shown in FIGS. 2 and 6. The plate chassis 204 includes a peripheral edge 268 extending between the top side 264 and the lower side 266 and defining a peripheral profile of the plate chassis 204.

The lower side 266 of the plate chassis 204 includes a plurality of protrusions configured to at least partially mate with the corresponding recesses formed in the upper side 216 of the plate shell 202. Thus, as previously explained, because the plate shell 202 is formed of a film material each of the protrusions 230, 232, 238, 248 formed on the bottom side 218 of the plate shell 202 results in a corresponding recess along the upper side 216 of the plate shell 202. The lower side 266 of the plate chassis 204 includes a protrusion 272, 274, 276, 286 configured to mate with each of these recesses and having the same configuration as described above with respect to the protrusions 230, 232, 238, 248 formed on the bottom side 218 of the plate shell 202. Thus, the lower side 266 of the plate chassis 204 includes a plurality of bosses 272 configured to mate with recesses associated with the frame attachment bosses 230 of the plate shell 202. The lower side 266 further includes a heel rib 274 configured to mate with the recess associated with the heel frame attachment rib 232 of the plate shell 202. Likewise, the lower side 266 includes an intermediate rib 276 and a medial rib 286 configured to mate with the recesses associated with the intermediate frame attachment rib 238 and the medial rib 248 of the plate shell 202. The intermediate rib 276 includes a concave sidewall 278 facing the medial side 22 and a convex sidewall 280 facing the lateral side 24. Each of the sidewalls 278, 280 extends continuously from an anterior end 282 to a posterior end 284. Similarly, the medial rib 286 is configured to mate with the recess associated with the medial rib 248 and includes a pair of sidewalls 288, 290 extending along an arcuate path between the forefoot region 12 and the heel region 16. Thus, when the article of footwear 10 is assembled, the strobel 104 of the upper 100 is captured between the mating protrusions 272, 274, 276, 286 and the corresponding recesses to mechanically lock the upper 100 relative to the sole structure 200.

Referring to FIGS. 1-7B, the plate frame 206 attaches to the bottom side 218 of the plate shell 202 and includes a first frame member 300 and a separate second frame member 302. The first frame member 300 extends along the forefoot region 12 to the heel region 16 and the second frame member 302 is isolated within the heel region 16. Collectively, the plate frame 206 and each of the frame members 300, 302 may be referred to as including an upper side 304 facing the bottom side 218 of the plate shell 202 and a bottom side 306 formed on an opposite side from the upper side 304. The bottom side 306 of the plate frame 206 defines a portion of the ground-engaging surface 26 of the sole structure 200.

The first frame member 300 includes an arcuate spine 308 attached to the intermediate frame attachment rib 238 of the plate shell 202 and extending from a first end 310 adjacent to the MTP axis A_MTP to a second end 312 located in the heel region 16. Similar to the intermediate frame attachment rib 238, the arcuate spine 314 may have a tapered cross-sectional profile (FIG. 13), whereby opposing sidewalls 332, 334 converge at a distal edge 336. Thus, while the arcuate spine 308 provides reinforcement along the bottom side 218 of the plate shell 202, the tapered profile of the arcuate spine 308 may also provide traction or engagement with a soft ground surface.

The first frame member 300 further includes an annular spine 314 disposed at the first end 310 of the arcuate spine 308. As best shown in FIG. 7A, the annular spine 314 extends along a circular path from a first terminal end 316 protruding from the first end 310 of the arcuate spine 308 to a second terminal end 318 adjacent to the lateral side 24. The first terminal end 316 faces and is spaced apart from the second terminal end 318 by a gap 317 through which the bottom side 218 of the plate shell 202 is exposed. Referring still to FIG. 7A, the first terminal end 316 of the annular spine 314 projects towards the lateral side 24 from the first end 310 of the arcuate spine 308.

The arcuate spine 314 includes a plurality of traction element bases 320a-320e arranged in series from the first terminal end 316 to the second terminal end 318. Accordingly, the traction element bases 320a-320e define an annular pattern that, when assembled with the traction element tips 422, define a rotational cleat pattern in the forefoot region 12. As discussed previously with respect to the traction element bases 259a, 259b and traction elements 210a, 210b of the medial rib 248, the traction element bases 320a-320e and traction element tips 422 define directional traction elements 210c-210g having a leading end 416 and a trailing end 418. The traction element bases 320a-320e of the annular spine 314 are arranged such each of the traction element bases 320a-320e and the corresponding traction elements 210c-210g is oriented in the same rotational direction along the annular spine 314. Specifically, the leading end 416 of the traction element 210c disposed at the first terminal end 316 faces the first terminal end 316. Thus, all of the traction elements 210c-210g associated with the annular spine 314 are oriented with the leading ends 416 facing in a rotational direction associated with rotation of the heel region 16 towards the lateral direction about the forefoot region (i.e., clock-wise in the right-footed sole structure shown in FIG. 7A) With continued reference to FIG. 7A, the first frame member 300 includes a distal rib 322 disposed at the second end 312 of the arcuate spine 308 and projecting to a distal end adjacent to the peripheral edge 220 of the plate shell 202 on the lateral side 24. The distal rib 322 defines a distal rib traction element base 324 configured to attach a traction element tip 422 to form another one of the traction elements 210h of the sole structure 200. The first frame member 300 further includes an intermediate rib 326 projecting from a proximal end attached to the arcuate spine 308 in the mid-foot region 14 to a distal end adjacent to the peripheral edge 220 of the plate shell 202 in the ball portion 12_B. As shown in FIG. 7A, a longitudinal axis of the intermediate rib 326 extends substantially perpendicular to the arcuate longitudinal axis of the arcuate spine 308. The intermediate rib 326 includes an intermediate rib traction element base 328 configured for attaching a traction element tip 422 to form another one of the traction elements 210i of the sole structure 200. Each of the traction elements 210h, 210i associated with the distal rib 322 and the intermediate rib 326 are oriented in the same rotational direction about the forefoot region 12 as the traction elements 210c-210g associated with the annular traction element bases 320a-320e, as described previously.

Referring to FIG. 6, the first frame member 300 includes an interior channel 329 formed in the upper side 304 and configured to receive the traction assembly 208 therein. Thus, at least a portion of the traction assembly 208 is interposed between the plate frame 206 and the bottom side 218 of the plate shell 202 when the sole structure 200 is assembled. The convex sidewall 334 of the arcuate spine 308 may include a plurality of recesses 330 arranged in series between the first end 310 and the second end 312. These recesses 330 function as passages for portions of the traction assembly 208 to extend through the convex sidewall 334 from the interior channel 329 and along the bottom side 218 of the plate shell 202. As best shown in FIG. 13, the upper side 304 of the arcuate spine 308 and an upper side of the traction assembly 208 are each contoured to mate with the intermediate frame attachment rib 238 of the plate shell 202, whereby an upper surface of the traction assembly 208 is substantially continuous with (i.e., immediately adjacent portions are flush) the upper side 304 of the arcuate spine 308.

The second frame member 302 is attached to the heel frame attachment rib 232 in the heel region 16 of the plate shell 202 and extends along an arcuate path from a first end 338 on the medial side 22 of the sole structure 200 to a second end 340 on the lateral side 24 of the sole structure 200. The second frame member 302 includes a pair of traction element bases 342a, 342b disposed at the opposite ends 338, 340 of the second frame member 302. The traction element bases 342a, 342b include a first traction element base 342a disposed at the first end 338 of the second frame member 302 and a second traction element base 342b disposed at the second end 340 of the second frame member 302. As with the traction element bases discussed previously, the traction element bases 342a, 342b of the second frame member 302 are configured for attaching a traction element tip 422 to define respective ones of the traction elements 210j, 210k of the sole structure 200. The traction elements 210 defined by the traction element bases 342a, 342b are configured as directional traction elements, whereby the first traction element base 342a defines a traction element 210j having a leading end 416 facing the medial side 22 and the second traction element base 342b defines a traction element 210k having a leading end 416 facing the lateral side 24.

The traction assembly 208 is attached to the bottom side 218 of the plate shell 202 and includes a material having a softer durometer than each of the plate shell 202 and the plate frame 206 to provide a resilient gripping interface along the bottom side 218 of the plate shell 202. As shown in FIGS. 5 and 6, the traction assembly 208 includes a first traction member 350 configured to provide ground engagement and a separate second traction member 352 configured to provide a combination of ground engagement and ball control. The traction assembly 208 and the individual traction members 350, 352 may be described as including an upper side 354 facing and attached to the bottom side 218 of the plate shell 202 and a bottom side 356 disposed on an opposite side from the upper side 354.

The first traction member 350 of the traction assembly 208 includes an arcuate spine 358 extending from a first end 360 in the forefoot region 12 to a second end 362 in the heel region 16. As shown in FIGS. 6 and 13, the arcuate spine 358 is received within the portion of the interior channel 329 of the first frame member 300 that is formed within the arcuate spine 308 of the first frame member 300. Thus, the ends 360, 362 of the arcuate spine 358 of the traction assembly 208 are respectively received within the ends 310, 312 of the arcuate spine 308 of the first frame member 300.

The traction assembly 208 further includes an annular spine 364 extending from a proximal end 366 attached to the first end 360 of the arcuate spine 358 to a distal end 368 disposed on the lateral side 24 of the sole structure 200. The annular spine 364 of the traction assembly 208 is received within the portion of the interior channel 329 defined by the annular spine 314 of the first frame member 300, whereby the annular spine 364 of the traction assembly 208 is disposed between the annular spine 314 of the first frame member 300 and the bottom side 218 of the plate shell 202. The annular spine 364 of the first traction member 350 includes a plurality of elongate bosses 370 corresponding to and configured to be received within recesses associated with the traction element bases 320a-320e of the first frame member 300.

With continued reference to FIGS. 5-7A, the first traction member 350 includes a traction pad 372 disposed within the forefoot region 12. The traction pad 372 is attached to the annular spine 364 and is exposed along the bottom side 218 of the plate shell 202 within the annular spine 314 of the first frame member 300. In other words, the traction pad 372 is at least partially surrounded by the annular spine 314. In the illustrated example, the traction pad 372 is circular and is concentric with the annular spine 364 of the first traction member 350. The bottom side 356 of the traction pad 372 includes a plurality of conical traction elements 374 protruding therefrom. As shown in FIG. 7A, the traction pad 372 is attached to the annular spine 364 by a plurality of spokes 382 extending radially outwardly from the outer circumference of the traction pad 372 to an inner edge of the annular spine 364. Optionally, the first traction member 350 may include an intermediate ring 384 disposed between the outer circumference of the traction pad 372 and the inner circumference of the annular spine 364. As shown in FIG. 7A, when included, the intermediate ring 384 extends continuously and entirely around the outer circumference of the traction pad 372.

The first traction member 350 further includes a distal protrusion 376 disposed at the second end 362 of the arcuate spine 364 and configured to mate with a portion of the interior channel 329 of the first frame member 300 formed in the upper side 304 of the distal rib traction element base 324. Similarly, the first traction member 350 includes an intermediate protrusion 378 extending towards the lateral side 24 of the sole structure 200 from an intermediate portion of the arcuate spine 364 in the mid-foot region 14. The intermediate protrusion 378 is configured to mate with a corresponding portion of the interior channel 329 formed in the upper side 304 of the intermediate stud traction element base 328. The protrusions 376, 378 cooperate with the first frame member 300 to secure the arcuate spine 364 and to minimize movement of the arcuate spine 364 in the longitudinal direction.

Referring still to FIGS. 5-7A, the first traction member 350 includes a plurality of elongate traction ribs 380 arranged in series between the first end 360 and the second end 362. As shown, the traction ribs 380 extend from the arcuate spine 364 towards the lateral side 24 of the sole structure. As discussed previously, the first frame member 300 includes a plurality of recesses 330 formed through the convex sidewall 334 along the upper side 304. Each of the traction ribs 380 extends through a respective one of the recesses 330 from the arcuate spine 364 disposed within the interior channel 329 and along a portion of the bottom side 218 of the plate shell 202 to a distal end 381 adjacent to the lateral side 24.

With continued reference to FIGS. 5-7A, the traction assembly 208 includes the second traction member 352 attached to and extending along the medial rib 248 of the plate shell. The second traction member 352 extends from a first end 390 adjacent to the first traction element base 259a to a second end 392 adjacent to the second traction element base 259b. Similar to the medial rib 248, the second traction member 352 has a tapered cross-section profile defined by a concave side 394 and an opposite convex side 396 that converge with each other at a distal edge 398. As shown in FIG. 7A, each of the concave side 394 and the convex side 396 extends continuously along an arcuate path corresponding to the path of the medial rib 248. The distal edge 398 of the second traction member 352 includes one or more notches 400 disposed between the first end 390 and the second end 392. These notches 400 function to separate the distal edge 398 into a plurality of flex zones along the length of the second traction member 352. The flex zones may provide increased flexibility along the distal edge 398 to aid in ball control.

The concave side 394 cooperates with medial sides of the first and second traction element bases 259a, 259b to provide a substantially continuous concave ball receiving zone 404 having a radius R₄₀₄ corresponding to an outer diameter of a soccer ball. Optionally, the concave side 394 may include a roughly textured surface or a plurality of gripping elements 402 (FIG. 3) formed as nubs or protrusions, which are configured to provide increased traction between the second traction member 352 and the soccer ball during ball handling.

As discussed previously, the various traction element bases 259, 320, 324, 328, 342 are each configured to receive a traction element tip 422 to define one of the traction elements 210a-210k of the sole structure. Each traction element 210a-210k includes tapering geometries that facilitate desirable traction properties. For example, a length of one or more of the traction elements 210a-210k may taper along a direction from the base to the tip. Particularly, at least one of the leading end 416 and the trailing end 418 may be formed at an oblique angle relative to the immediately adjacent surface of the bottom side 218 of the plate shell 202, whereby the leading end 416 and the trailing end 418 converge with each other along the direction from the bottom side 218 to the distal tip 414. Here, a relative angle between the leading end 416 and the bottom side 218 of the plate shell 202 may be less than an angle between the trailing end 418 and the bottom side 218 of the plate shell 202.

In addition to the tapered length, each traction element 210a-210k may include a tapering width (i.e., distance between a first side 410 and a second side 412). For instance, the traction elements 210a-210k may taper along the direction from the trailing end 418 to the leading end 416. Thus, the width of each traction element 210a-210k is greater at the trailing end 418 than at the leading end 416. The width of each traction element 210a-210k may also taper along the direction from the base 259a, 259b, 320a-320b, 324, 328, 342a, 342b to the distal tip 414. Accordingly, each of the traction elements 210a-210k may be described as including a compound taper, whereby the width tapers along the lengthwise direction and the height direction.

The combination of the tapering width(s) and length may be configured to optimize traction properties for each traction element. For example, the leading end 416 may be provided at less of an incline than the trailing end 418, whereby the leading end 416 functions to knife through a ground surface while the trailing end 418 functions to engage the ground surface to minimize movement through the ground surface in a direction towards the trailing end 418. Likewise, the tapering width along the height direction facilitates insertion of the traction elements 210a-210k into the ground surface, while the tapering width along the lengthwise direction facilitates a knifing property as each traction element 210a-210k moves through the ground surface in a direction towards the leading end 416.

In the illustrated example, the traction elements 210a-210k are formed as composite structures, whereby portions of the traction elements 210a-210k are defined by various components and/or materials. For example, the base 259a, 259b, 320a-320b, 324, 328, 342a, 342b of each traction element 210a-210k is defined by the plate shell 202 or the plate frame 206 while the distal tip 414 of each traction element 422 is defined by a traction element tip 422 that is formed separately and attached to the base 259a, 259b, 320a-320b, 324, 328, 342a, 342b. In this example, the attachment interface is provided by a bonding relationship between the traction element tips 422 and a corresponding socket 420 formed at the distal end of each base 259a, 259b, 320a-320b, 324, 328, 342a, 342b. Bonding may be accomplished by directly bonding the materials of the traction element tips 422 and the base 259a, 259b, 320a-320b, 324, 328, 342a, 342b during a co-molding process or by including an additional adhesive material between the attachment surfaces.

The sole structure 200 may be manufactured using an injection molding process, whereby the materials of one or more of the sole structure components 202, 204, 206, 208, 210 are molded or co-molded using an injection molding process. Materials of the plate shell 202 and each of the plate frame 206 and the traction assembly 208 may be selected to provide enhanced bonding properties between the plate shell 202, the plate frame 206, and the traction assembly 208 during molding. For example, the components 202, 206, 208 may each include a thermoplastic polyurethane (TPU) material to enhance bonding between the components. The material of the plate shell 202 may have a Shore hardness ranging from 80 A to 95 A, the material of the plate frame 206 may have a Shore hardness ranging from 90 A to 95 A, and the material of the traction assembly 208 may have a Shore hardness ranging from 80 A to 85 A. Thus, the plate shell 202 provides a relatively hard, yet thin layer providing a ground-engaging surface 26 and a support body for the components 206, 208.

With particular reference to FIGS. 17-33, an article of footwear 10a is provided and includes the upper 100 and a sole structure 200a. In view of the substantial similarity in structure and function of the components associated with the article of footwear 10 with respect to the article of footwear 10a, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.

Referring to FIGS. 17-22, the sole structure 200a includes a plate shell 202a disposed on a bottom side of the strobel 104 and a plate chassis 204a disposed within the upper 100 and on an opposite side of the strobel 104 from the plate shell 202a. Thus, when the sole structure 200a is assembled with the upper 100, the strobel 104 of the upper 100 is interposed between the plate chassis 204a and the plate shell 202a. The plate shell 202a cooperates with the strobel 104 to form an exterior portion of the article of footwear 10 and defines at least a portion of a ground-engaging surface 26 of the sole structure 200a. In this example, the plate shell 202a is formed as a fragmentary structure including a forefoot plate shell segment 203a disposed in the forefoot region 12 of the sole structure 200a and a heel plate shell segment 203b disposed in the heel region 16 of the sole structure 200a.

The sole structure 200a further includes a plate frame 206a attached to the plate shell 202a on an opposite side from the plate chassis 204. The plate frame 206a defines a second portion of the ground-engaging surface 26 of the sole structure 200a. In this example, the plate frame 206a includes a first frame member 300a surrounding the periphery of the forefoot plate shell segment 203a and a second frame member 302b surrounding the periphery of the heel plate shell segment 203b.

Referring still to FIGS. 17-22, the plate shell 202a includes the forefoot plate shell segment 203a that extends from a first end 212a of the plate shell 202a at the anterior end 18 of the sole structure 200a to an intermediate posterior end 213a disposed in the mid-foot region 14 of the sole structure 200a. The plate shell 202a further includes the heel plate shell segment 203b that extends from the second end 214a of the plate shell 202a at the posterior end 20 of the sole structure 200a to an intermediate anterior end 215a disposed in the heel region 16. As best shown in FIG. 23A, the posterior end 213a of the forefoot plate shell segment 203a opposes and is spaced apart from the anterior end 215a of the heel plate shell segment 203b by a gap 217a extending through the mid-foot region 14. When the sole structure 200a is assembled with the upper 100, the strobel 104 of the upper 100 is exposed through the gap 217a and forms a portion of the ground-engaging surface 26 along the mid-foot region 14 of the article of footwear 10a.

The plate shell segments 203a, 203b collectively define an upper side 216a of the plate shell 202a that is configured to face the strobel 104 of the upper 100 when the sole structure 200a is assembled with the upper 100. The plate shell segments 203a, 203b further define a bottom side 218a of the plate shell 202a formed on an opposite side from the upper side 216a, whereby a distance from the upper side 216a to the bottom side 218a defines a thickness T_202a (FIG. 27) of the plate shell 202a. The bottom side 218a of the plate shell 202a defines a first portion of the ground-engaging surface 26 of the article of footwear 10 when then sole structure 200a is assembled with the upper 100.

The plate shell segments 203a, 203b respectively include peripheral edges 220a, 220b that extend between the upper side 216a and the bottom side 218a and define an outer peripheral profile of each of the plate shell segments 203a, 203b. The peripheral edges 220a, 220b define convex curvatures along each of the first end 212a and the second end 214a, whereby a radius of the curvature at the first end 212a of the forefoot plate shell segment 203a corresponds to a ball of the foot and a radius of the curvature at the second end 214a of the heel plate shell segment 203b corresponds to a heel of the foot and is generally smaller than the radius at the first end 212a.

Referring to FIG. 23A, the forefoot plate shell segment 203a may be described as including a full-width portion 219a disposed in the toe portion 12_T of the forefoot region 12 and a tapered portion 219b extending along the lateral side 24 towards the posterior end 20 from the full-width portion 219a. The full-width portion 219a of the forefoot plate shell segment 230a has a width W_219a that extends continuously across the width of the sole structure 200a from the medial side 22 to the lateral side 24. As shown in FIG. 21, the full-width portion 219a includes a circular opening 223a extending through the thickness of the forefoot plate shell segment 203a. The opening 223a is centered along the longitudinal axis A_10a. The tapered portion 219b has a width W_219b that tapers towards the lateral side 24 along the direction from the full-width portion 219a to the posterior end 213a.

Referring to FIG. 21, the bottom side 218a of the full-width portion 219a of the forefoot plate shell segment 203a includes a plurality of the traction element bases 320a-320e arranged in an annular pattern within the forefoot region 12 around the opening 223a. Accordingly, the traction element bases 320a-320e define an annular pattern that, when assembled with the traction element tips 422, define a rotational cleat pattern in the forefoot region 12. As discussed previously with respect to the sole structure 200, the traction element bases 320a-320e and traction element tips 422 define the directional traction elements 210c-210g having a leading end 416 and a trailing end 418. The traction element bases 320a-320e of the forefoot plate shell segment 203a are arranged such each of the traction element bases 320a-320e and the corresponding traction elements 210c-210g is oriented in the same rotational direction within the forefoot plate shell segment 203a. Thus, all of the traction elements 210c-210g associated with the forefoot plate shell segment 203a are oriented with the leading ends 416 facing in a rotational direction associated with rotation of the heel region 16 towards the lateral direction about the forefoot region (i.e., clock-wise in the right-footed sole structure shown in FIG. 23A). The tapered portion 219b of the forefoot plate shell segment 203a includes the intermediate lateral traction element base 328 configured for attaching a traction element tip 422 to form another one of the traction elements 210i of the sole structure 200. The traction element 210i is oriented in the same rotational direction about the forefoot region 12 as the traction elements 210c-210g associated with the annular traction element bases 320a-320e, as described previously.

Referring to FIG. 23A, the heel plate shell segment 203b may be described as including a full-width portion 221a disposed at the second end 214a and a tapered portion 221b extending along the lateral side 24 towards the anterior end 215a from the full-width portion 219a. The full-width portion 221a of the heel plate shell segment 203b has a width W_221a that extends continuously across the width of the sole structure 200a from the medial side 22 to the lateral side 24. The tapered portion 221b has a width W_221b that tapers towards the lateral side 24 along the direction from the full-width portion 221a to the anterior end 215a.

The bottom side of the heel plate shell segment 203b includes the plurality of the traction element bases 324, 342a, 342b. The traction element bases 324, 342a, 342b include an anterior traction element base 324 formed adjacent to the anterior end 215a along the lateral side 24 and having the same configuration and orientation as the distal rib traction element base 324 discussed previously with respect to the sole structure 200. The traction element bases 324, 342a, 342b further include a first posterior traction element base 342a disposed at the second end 214a of the heel plate shell segment 203b on the lateral side 24 and the second traction element base 342b disposed at the second end 214a of the heel plate shell segment 203b on the medial side 24. As with the traction element bases discussed previously, the traction element bases 324, 342a, 342b of the heel plate shell segment 203b are configured for attaching a traction element tip 422 to define respective ones of the traction elements 210h, 210j, 210k of the sole structure 200a. The traction elements 210j, 210k defined by the traction element bases 342a, 342b are configured as directional traction elements, whereby the first traction element base 342a defines a traction element 210j having a leading end 416 facing the medial side 22 and the second traction element base 342b defines a traction element 210k having a leading end 416 facing the lateral side 24. The traction element 210h is oriented in the same rotational direction about the forefoot region 12 as the traction elements 210c-210g associated with the annular traction element bases 320a-320e, as described previously.

Referring to FIGS. 21-23B, the plate frame 206a attaches to the respective peripheral flanges 220a, 220a of the plate shell segments 203a, 203b and includes a first frame member 300a and a separate second frame member 302a. Collectively, the plate frame 206a and each of the frame members 300a, 302a may be referred to as including an upper side 304a facing the strobel 104 of the upper 100 and a bottom side 306a formed on an opposite side from the upper side 304a. The bottom side 306a of the plate frame 206a defines a portion of the ground-engaging surface 26 of the sole structure 200a.

The first frame member 300a includes a first peripheral rim 307a that attaches to and surrounds the peripheral edge 220a of the forefoot plate shell segment 203a. Thus, the first frame member 300a provides a continuous boundary along the peripheral edge 220a of the forefoot plate shell segment 203a. The first frame member 300a further includes a medial extension element 309a extending outwardly from the first peripheral rim 307a in the medial direction. As best shown in FIG. 23A, when the sole structure 200a is assembled, the medial extension element 309a extends towards the medial side 22 from the tapered portion 219b of the forefoot plate shell segment 203a, between the full-width portion 219a and the posterior end 213a. The medial extension element 309a includes the traction element base 259a discussed previously.

The second frame member 302a includes a second peripheral rim 307b that attaches to and surrounds the peripheral edge 220b of the heel plate shell segment 203b. Thus, the second frame member 302a provides a continuous boundary along the peripheral edge 220b of the heel plate shell segment 203b. The second frame member 302a further includes a medial extension element 309b extending outwardly from the second peripheral rim 307b in the medial direction. As best shown in FIG. 23A, when the sole structure 200a is assembled, the medial extension element 309b extends towards the medial side 22 from the tapered portion 221b of the heel plate shell segment 203b, between the full-width portion 221a and the anterior end 215a. The medial extension element 309b includes the traction element base 259b discussed previously.

Referring again to FIGS. 21 and 22, the plate chassis 204a is configured to mate with the upper side 216a of the plate shell 202a and the plate frame 206a, whereby the strobel 104 of the upper 100 is captured between the plate chassis 204a on the top side and the plate shell 202a and plate frame 206a on the bottom side. The plate chassis 204a is a full-length plate chassis 204 that extends from a first end 260a at the anterior end 18 of the article of footwear 10 to a second end 262a at the posterior end 20 of the article of footwear 10. The plate chassis 204a includes a top side 264a and a lower side 266a formed on an opposite side from the top side 264a. A distance from the top side 264a to the lower side 266a defines a thickness of the plate chassis 204a. The plate chassis 204a may be a molded component having a variable thickness and various reinforcing elements, such as integrated ribs and lattice structures shown in FIGS. 18 and 22. The plate chassis 204a includes a peripheral edge 268a extending between the top side 264a and the lower side 266a and defining a peripheral profile of the plate chassis 204a.

The peripheral edge 268a includes a mid-foot recess 270a defined by a concave portion of the peripheral edge 268a extending continuously from a first end adjacent to the forefoot region 12 to a second end adjacent to the heel region 16. The peripheral edge 268a further includes a forefoot recess 271a defined by a concave portion of the peripheral edge 268a extending from a first end in the ball portion 12_B to a second end in the toe portion 12_T of the forefoot region 12. An apex of the forefoot recess 271a is aligned along a metatarsophalangeal (MTP) axis A_MTP of the sole structure 200 (FIG. 23A). Thus, the forefoot recess 271a provides a relief region along the medial side of the plate chassis 204 along which the toe portion 12_T can flex relative to the ball portion 12_B.

The lower side 266a includes a lateral rib 276a extending along the lateral side 24 of the sole structure 200a from the forefoot region 12 to the heel region 16. The lateral rib 276a includes a concave sidewall 278a facing the lateral side and a convex sidewall 280a facing the medial side 24. The lateral rib 276a is defined by the cooperation of a pair of sidewalls 278a, 280a that each extend from the bottom side 266a of the plate chassis 204a and converge with each other at a distal edge 281a (FIG. 21). Thus, a width of the lateral rib 276a (i.e., the distance measured across the sidewalls 278a, 280a) tapers along a direction from the bottom side 266a of the plate chassis 204a to the distal edge 281a of the lateral rib 276a. The lateral rib 276a and each of the sidewalls 278a, 280a extend continuously along an arcuate path from an anterior end 282a adjacent to the forefoot region 12 to a posterior end 284a adjacent to the heel region 16. Thus, the first sidewall 278a that faces the lateral side 24 of the sole structure 200a defines a concave side of the lateral rib 276a while the second sidewall 280a that faces the medial side 22 of the sole structure 200a defines a convex side of the lateral rib 276a.

With continued reference to FIG. 21, the plate chassis 204a includes a medial rib 286a extending along a portion of the peripheral edge 268a defining the mid-foot recess 270a on the medial side 22 of the plate chassis 204a. The medial rib 286a is defined by the cooperation of a pair of sidewalls 288a, 290a that each extend from the bottom side 266a of the plate chassis 204a and converge with each other at a distal end 292a (FIG. 30). Thus, a width of the medial rib 286a (i.e., the distance measured across the sidewalls 288a, 290a) tapers along a direction from the bottom side 266a of the plate chassis 204a to the distal end 292a of the medial rib 286a. The medial rib 286a and each of the sidewalls 288a, 290a extends continuously along an arcuate path from an anterior end 294a adjacent to the forefoot region 12 to a posterior end 296a adjacent to the heel region 16. Thus, the first sidewall 288a that faces the medial side 22 of the sole structure 200a defines a concave side of the medial rib 286a while the second sidewall 290a that faces the lateral side 24 of the sole structure 200a defines a convex side of the medial rib 286a.

As shown in FIGS. 21 and 23A, the medial rib 286a includes a pair of traction element bosses 298a, 298b respectively formed at opposite ends of the medial rib 286a. Particularly, the medial rib 286a includes a first traction element boss 298a disposed at the anterior end 294a of the medial rib 286a and a second traction element boss 298b disposed at the posterior end 296a of the medial rib 286a. Each of the traction element bosses 298a, 298b is configured to mate with a respective one of the traction element bases 259a, 259b defined by the extension elements 309a, 309b of the plate frame 206a. The concave sidewall 288a cooperates with medial sides of the first and second traction element bases 259a, 259b to provide the substantially continuous concave receiving zone 404 having a radius R₄₀₄ corresponding to an outer diameter of a soccer ball.

Generally, when assembled with the traction element tips 422, the traction element bases 259a, 259b of the extension elements 309a, 309b define directional traction elements 210a, 210b having a longitudinal axis extending along a direction from a leading end 416 to an opposite trailing end 418. As shown in FIG. 23A, the traction element bases 259a, 259b are configured such that the longitudinal axes of the traction elements 210a, 210b are aligned with a longitudinal axis of the medial rib 286a. In other words, the lengths of the traction elements 210a, 210b and the corresponding traction element bases 259a, 259b extend along the same arcuate path as the medial rib 286a. The traction element bases 259a, 259b are oriented in opposite directions at each of the anterior end 294a and the posterior end 296a such that the respective trailing ends 418 face the corresponding ends 294a, 296a. Thus, the leading end 416 of the traction element 210a associated with the first traction element base 259a faces away from the anterior end 294a (i.e., toward the posterior end 296a) and the leading end 416 of the traction element 210b associated with the second traction element base 259b faces away from the posterior end 296a (i.e., towards the anterior end 294a).

With continued reference to FIGS. 21-23A, the traction assembly 208a includes a traction pad 372a disposed within the forefoot region 12. In the illustrated example, the traction pad 372a is circular and is disposed within the opening 223a of the forefoot plate shell segment 203a. The traction pad 372a includes an annular peripheral rim 386a having a distal edge that attaches to the plate shell 202a within the opening 223a. The traction pad 372a further includes a central protrusion 388a having a height H_388a extending downwardly from the peripheral rim 386a (FIG. 26). As shown in FIG. 26, the central protrusion 388a is formed as a conical structure having an interior void 389a on a top side associated with the peripheral rim 386a. Further, the traction pad 372a is formed of a resilient polymeric material including a lower durometer and higher coefficient of friction than the surrounding material of the plate shell 202a. In use, the central protrusion 388a may compress or collapse to accommodate forces applied during ball handling and movement. Particularly, the central protrusion 388a may provide a resilient gripping element for engaging a ball using forefoot region 12 of the sole structure 200a.

With reference to FIGS. 34 and 35, an alternative example of a traction pad 372b is shown. The traction pad 372b is configured to be used with the traction assembly 208a of sole structure 200a as an alternative solution to the traction pad 372a. In the illustrated example, the traction pad 372b is circular and is configured to be disposed within the opening 223a of the forefoot plate shell segment 203a. The traction pad 372b includes an annular peripheral rim 386a having a distal edge that attaches to the plate shell 202a within the opening 223a. The traction pad 372b includes a plurality of elongate protrusions 388b arranged in an annular pattern and each having a height H_388b (FIG. 35) extending downwardly from the peripheral rim 386b. As shown in FIGS. 34 and 35, the elongate protrusions 388b each have a length extending along an arcuate path associated with and partially defining the annular arrangement of the protrusions 388b. Further, the traction pad 372b is formed of a resilient polymeric material including a lower durometer and higher coefficient of friction than the surrounding material of the plate shell 202a. In use, the elongate protrusions 388b may flex, compress, or collapse to accommodate forces applied during ball handling and movement. Particularly, the elongate protrusions 388b may provide a resilient gripping element for engaging a ball using forefoot region 12 of the sole structure 200a. The heights H_388b of the elongate protrusions 388b are greater than the heights H₂₁₀ (FIG. 17) of the traction elements 210c-210g. Thus, in use, the distal tips of the elongate protrusions 388b are configured to extend beyond the distal tips of the traction elements 210c-210g to allow the resilient elongate protrusions 388b to engage a ball before the traction elements 210c-210g.

As discussed previously, the various traction element bases 259a, 259b, 320a-320e, 324, 328, 342a, 342b are each configured to receive a traction element tip 422 to define one of the traction elements 210a-210k of the sole structure. Each traction element 210a-210k includes tapering geometries that facilitate desirable traction properties. For example, a length of one or more of the traction elements 210a-210k may taper along a direction from the base to the tip. Particularly, at least one of the leading end 416 and the trailing end 418 may be formed at an oblique angle relative to the immediately adjacent surface of the bottom side 218a of the plate shell 202a, whereby the leading end 416 and the trailing end 418 converge with each other along the direction from the bottom side 218a to the distal tip 414. Here, a relative angle between the leading end 416 and the bottom side 218a of the plate shell 202a may be less than an angle between the trailing end 418 and the bottom side 218a of the plate shell 202a.

In addition to the tapered length, each traction element 210a-210k may include a tapering width (i.e., distance between a first side 410 and a second side 412). For instance, the traction elements 210a-210k may taper along the direction from the trailing end 418 to the leading end 416. Thus, the width of each traction element 210a-210k is greater at the trailing end 418 than at the leading end 416. The width of each traction element 210a-210k may also taper along the direction from the base 259a, 259b, 320a-320b, 324, 328, 342a, 342b to the distal tip 414. Accordingly, each of the traction elements 210a-210k may be described as including a compound taper, whereby the width tapers along the lengthwise direction and the height direction.

The combination of the tapering width(s) and length may be configured to optimize traction properties for each traction element. For example, the leading end 416 may be provided at less of an incline than the trailing end 418, whereby the leading end 416 functions to knife through a ground surface while the trailing end 418 functions to engage the ground surface to minimize movement through the ground surface in a direction towards the trailing end 418. Likewise, the tapering width along the height direction facilitates insertion of the traction elements 210a-210k into the ground surface, while the tapering width along the lengthwise direction facilitates a knifing property as each traction element 210a-210k moves through the ground surface in a direction towards the leading end 416.

In the illustrated example, the traction elements 210a-210k are formed as composite structures, whereby portions of the traction elements 210a-210k are defined by various components and/or materials. For example, the base 259a, 259b, 320a-320b, 324, 328, 342a, 342b of each traction element 210a-210k is defined by the plate shell 202a or the plate frame 206a while the distal tip 414 of each traction element 422 is defined by a traction element tip 422 that is formed separately and attached to the base 259a, 259b, 320a-320b, 324, 328, 342a, 342b. In this example, the attachment interface is provided by a bonding relationship between the traction element tips 422 and a corresponding socket 420 formed at the distal end of each base 259a, 259b, 320a-320b, 324, 328, 342a, 342b. Bonding may be accomplished by directly bonding the materials of the traction element tips 422 and the base 259a, 259b, 320a-320b, 324, 328, 342a, 342b during a co-molding process or by including an additional adhesive material between the attachment surfaces.

Optionally, the sole structure 200a includes a heel counter 211a attached to the plate chassis 204a in the heel region 16. Accordingly, the heel counter 211a is disposed within the interior void 102 of the upper 100 when the article of footwear 10a is assembled. As best shown in FIGS. 24 and 31-33, the heel counter 211a extends continuously around the posterior end 20 of the article of footwear 10a from a first end 426a on the medial side 22 of the heel region 16 to a second end 428a on the lateral side 24 of the heel region 16. The heel counter 211a includes a heel counter base flange 430a that mates with the peripheral edge 268a of the plate chassis 204a and a heel counter wall 432a that extends upwardly from the heel counter base flange 430a to a distal edge 434a. Optionally, the heel counter base flange 430a includes a pair of attachment tabs 436a, 436b that mate with corresponding recesses formed along the upper side 216a of the heel plate shell segment 203b. The heel counter 211a provides increased support around the heel region 16 of the upper 100.

The sole structure 200a may be manufactured using an injection molding process, whereby the materials of one or more of the sole structure components 202a, 204a, 206a, 208a, 210a, 211a are molded or co-molded using an injection molding process. Materials of the plate shell 202a and each of the plate frame 206a and the traction assembly 208a may be selected to provide enhanced bonding properties between the plate shell 202a, the plate frame 206a, and the traction assembly 208a during molding. For example, the components 202a, 206a, 208a, 211a may each include a thermoplastic polyurethane (TPU) material to enhance bonding between the components. The material of the plate shell 202a may have a Shore hardness ranging from 80 A to 95 A, the material of the plate frame 206a may have a Shore hardness ranging from 90 A to 95A, and the material of the traction assembly 208a may have a Shore hardness ranging from 80 A to 85 A. Thus, the plate shell 202a provides a relatively hard layer providing a ground-engaging surface 26 and a support body for the components 206a, 208a.

The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.