SOLE FOR ARTICLE OF FOOTWEAR HAVING DETACHABLE TRACTION ELEMENTS AND METHOD OF MANUFACTURING THEREOF

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/673,448, entitled “SOLE FOR ARTICLE OF FOOTWEAR HAVING DETACHABLE TRACTION ELEMENTS,” filed Jul. 19, 2024, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

Embodiments of this invention relate to an article of footwear and, more specifically, to embodiments of a sole for an article of footwear having detachable traction elements and methods of manufacturing the same.

BACKGROUND

Conventional articles of footwear, e.g., track shoes, for sporting events such as track and field events, can include soles with sole plates having spikes disposed thereon to provide grip on an event surface, e.g., a track surface. During a stride of a runner wearing a track shoe, the sole plate of the track shoe can provide progressive flexure and energy storage during a loading phase of a running stride, with the loading phase of the skating stride including dorsiflexion of the wearer's foot to a dorsiflexed position. Further, the sole plate of the track shoe can provide an energy return that is based on the energy storage during an unloading phase of the running stride, with the unloading phase of the running stride including recovery of the wearer's foot to a neutral position from the dorsiflexed position. For performance purposes, it is desirable to increase rigidity and stiffness of the sole plates to provide an increased energy return during a running stride, while also minimizing a weight of materials included in the sole plates to reduce fatigue for a wearer. In response, fiber reinforced materials have been used in sole plates to provide such increased rigidity and stiffness and reduced weight relative to conventional materials, e.g., thermoplastic elastomers such as thermoplastic polyurethane (TPU). As an example, carbon fiber reinforced materials have been added to sole plates of track shoes to provide increased stiffness to the sole of the track shoe, thereby increasing an energy return to wearers of the track shoes during a running stride.

Commonly, spikes of the sole plates of track shoes can be permanently attached to the sole plates or detachably coupled to the sole plates via a number of mounting receptacles included in the sole plate. Receptacles can be included in areas of a sole plate of a track shoe, such that detachable spikes can be removably fastened to the receptacles and coupled to the sole plate. However, permanently attached spikes can provide the advantages of weight reduction and enhanced traction relative to detachable spikes, as sole plates having mounting receptacles for detachable spikes tend to have worse traction. For example, areas of a sole plate including mounting receptacles for detachable spikes conventionally protrude outward from the sole plate towards a ground surface, thereby providing a gap between other areas of the sole plate and the ground surface during contact between the sole plate and the ground surface.

Detachable spikes can provide the advantage of allowing replacement of spikes to adhere to different sporting requirements. For example, detachable spikes of different configurations (e.g., sizes, lengths, widths, etc.) can be used to comply with requirements for different track and field events, weather conditions, and skill levels. Further, for a track shoe including a sole plate with mounting receptacles for detachable spikes, the detachable spikes can be replaced once degraded after repeated use of the track shoe, thereby increasing the track shoe's longevity. Finally, the ability to remove detachable spikes from the sole plate of a track shoe can reduce degradation of ground, e.g., track, surfaces on which the track shoes are worn, as the detachable spikes can be removed from the track shoes and the track shoes can be worn on ground surfaces without the detachable spikes when sporting events are not taking place. However, due to a lack of suitable manufacturing techniques, soles and sole plates have yet to be developed that integrate the advantages of fiber, e.g., carbon fiber, reinforced sole plates with mounting receptacles for use with detachable spikes. As an example, injection molding techniques used to manufacture conventional sole plates including receptacles for detachable spikes are inapplicable to the manufacturing of carbon fiber sole plates.

SUMMARY

Accordingly, it is desirable to provide an improved sole for an article of footwear that overcomes the shortcomings of the prior art. Although embodiments of the invention are described herein for the particular use of an article of footwear for track and field events, those of ordinary skill in the art can appreciate the applicability of the technologies described herein to other uses associated with footwear.

In an aspect, embodiments relate to a sole for an article of footwear. The sole includes a midsole including a top midsole surface and a bottom midsole surface, the bottom midsole surface defining an indentation (e.g., a plurality of indentations). The sole includes a carbon fiber sole plate including a top plate surface attached to the bottom midsole surface, a bottom plate surface configured to contact a ground surface, and a forefoot plate area, the carbon fiber sole plate (e.g., bottom plate surface) defining a cavity. The sole includes a mounting receptacle (e.g., plurality of mounting receptacles) disposed within the cavity (e.g., the plurality of cavities) of the carbon fiber sole plate. The sole includes a traction element (e.g., a plurality of traction elements) configured to detachably couple to the mounting receptacle.

One or more of the following features may be included in any combination. The top plate surface can define a convex structure in the forefoot plate area, the convex structure being received by the indentation in the midsole. In some variations, a sidewall of the cavity can be formed by an inner surface of the convex structure. In some variations, the mounting receptacle can engage with the sidewall of the cavity within which the mounting receptacle is disposed. The carbon fiber sole plate (e.g., bottom plate surface) can define the cavity in the forefoot plate area. The mounting receptacle can include a first fastener. In some variations, the traction element can include a projection and a second fastener. In some variations, the traction element can be configured to detachably couple to the mounting receptacle via engagement between the first and second fasteners. The midsole can further include a forefoot midsole area and the bottom midsole surface can define the indentation in the forefoot midsole area of the midsole. The carbon fiber sole plate can further include a midfoot plate area and a heel plate area and the midfoot plate area can extend between the forefoot plate area and the heel plate area. In some variations, the bottom plate surface can define a corrugation extending along the midfoot plate area. The carbon fiber sole plate can further including at least one layer comprising carbon fibers and a resin. The bottom plate surface can define a secondary traction element in the forefoot plate area. The mounting receptacle can include metal. The mounting receptacle can include an outer surface engaged with a sidewall of the cavity within which the mounting receptacle is disposed and the sidewall can retain the mounting receptacle. In some variations, the outer surface of the mounting receptacle can define at least one of (i) a plurality of teeth or (ii) one or more flanges. The mounting receptacle can include a bottom surface configured to contact the ground surface and the bottom surface of the mounting receptacle can be flush with (e.g., coplanar with) the bottom plate surface. The traction element can include a projection protruding from the mounting receptacle away from the bottom plate surface. In some variations, the projection further can include a spike. The traction element can be configured to extend from the cavity in the carbon fiber sole plate (e.g., bottom plate surface). The traction element can include metal.

In another aspect, embodiments relate to a method of fabricating a sole for an article of footwear. The method includes forming a carbon fiber sole plate including a top plate surface, a bottom plate surface configured to contact a ground surface, a forefoot plate area, a midfoot plate area, a heel plate area, and a mounting receptacle (e.g., a plurality of mounting receptacles). The method includes attaching the carbon fiber sole plate to a midsole including a top midsole surface and a bottom midsole surface. The method includes detachably coupling a traction element (e.g., a plurality of traction elements) to the mounting receptacle (e.g., the plurality of mounting receptacles) of the carbon fiber sole plate.

One or more of the following features may be included in any combination. Forming the carbon fiber sole plate can include placing one or more shaped layers into a sole plate mold, where at least one of the shaped layers includes one or more sublayers including carbon fibers, glass fibers, glass fleece prepreg, and/or resin. Forming the carbon fiber sole plate can include placing the mounting receptacle into the sole plate mold into an opening defined by the one or more shaped layers. Forming the carbon fiber sole plate can include molding the carbon fiber sole plate by applying at least one of (e.g., both) heat and pressure to the one or more shaped layers and the mounting receptacle within the sole plate mold and removing the carbon fiber sole plate from the sole plate mold. In some variations, applying the at least one of heat and the pressure to the one or more shaped layers and the mounting receptacle within the sole plate mold can cause the one or more shaped layers to conform (i) around the mounting receptacle and (ii) to a shape of the sole plate mold. The one or more shaped layers can include two or more shaped layers, and forming the carbon fiber sole plate can include applying, after placement of the two or more shaped layers into the sole plate mold, a vacuum to the two or more shaped layers to vacuum form the two or more shaped layers. Detachably coupling the traction element to the mounting receptacle of the carbon fiber sole plate can further include detachably coupling the traction element to the mounting receptacle of the carbon fiber sole plate before or after the forming of the carbon fiber sole plate.

In another aspect, embodiments relate to a sole for an article of footwear. The sole includes a midsole including a top midsole surface and a bottom midsole surface, the bottom midsole surface defining a recess. The sole includes a holding plate including a top holding surface and a bottom holding surface, the top holding surface attached to the recess of the bottom midsole surface, and where the holding plate (e.g., bottom holding surface) defines a cavity. The sole includes a carbon fiber sole plate including a top plate surface and a bottom plate surface, the top plate surface attached to both of the bottom midsole surface and the bottom holding surface, where the bottom plate surface is configured to contact a ground surface. The sole includes a mounting receptacle disposed within the cavity of the holding plate (e.g., bottom holding surface). The sole includes a traction element configured to detachably couple to the mounting receptacle.

One or more of the following features may be included in any combination. The mounting receptacle can engage with a sidewall of the cavity within which the mounting receptacle is disposed. The mounting receptacle can include a bottom surface configured to contact the ground surface and bottom surface of the mounting receptacle can be flush (e.g., coplanar) with at least one of (e.g., both of) the bottom plate surface or a portion of the bottom holding surface. At least a portion of the bottom holding surface surrounding the mounting receptacle can be configured to contact the ground surface and the portion of the bottom holding surface can be flush (e.g., coplanar) with the bottom plate surface. The bottom midsole surface can define an indentation disposed within the recess and the top holding surface can define a convex structure received by the indentation. In some variations, a sidewall of the cavity can be formed by an inner surface of the convex structure. The midsole can further include a forefoot midsole area and the bottom midsole surface can define the recess and the indentation in the forefoot midsole area. The carbon fiber sole plate can define an opening extending between the top plate surface and the bottom plate surface and the opening can receive at least a portion of the traction element. The bottom holding surface can define a convex structure. In some variations, a sidewall of each cavity can be formed by an inner surface of the convex structure. The carbon fiber sole plate can define an opening extending between the top plate surface and the bottom plate surface and the opening receives at least a portion of the convex structure and at least a portion of the traction element. The midsole can further include a forefoot midsole area and the bottom midsole surface can define the recess in the forefoot midsole area. The mounting receptacle can include a first fastener. The traction element can include a projection and a second fastener. The traction element can be configured to detachably couple to the mounting receptacle via engagement between the first and second fasteners.

In another aspect, embodiments relate to a method of fabricating a sole for an article of footwear. The method includes forming a holding plate including a top holding surface, a bottom holding surface, and a mounting receptacle. The method includes attaching the holding plate to a midsole including a top midsole surface and a bottom midsole surface, where the bottom midsole surface defines a recess in a forefoot midsole area of the midsole, and where the holding plate is disposed within the recess. The method includes forming a carbon fiber sole plate including a top plate surface, a bottom plate surface configured to contact a ground surface, a forefoot plate area, a midfoot plate area, and a heel plate area. The method includes attaching the carbon fiber sole plate to the midsole and the holding plate, where the top plate surface of the carbon fiber sole plate is attached to the bottom midsole surface and the bottom holding surface. The method includes detachably coupling a traction element to the mounting receptacle of the holding plate.

One or more of the following features may be included in any combination. Forming the holding plate can further include forming the holding plate by injection molding. In some variations, forming the holding plate can further include placing the mounting receptacle within an injection mold, injecting an elastomer material into the injection mold to form the holding plate, and removing the holding plate from the injection mold. In some variations, forming the holding plate can further include injecting an elastomer material into an injection mold to form a holding plate shell, removing the holding plate shell from the injection mold, and coupling the mounting receptacle to the holding plate shell to form the holding plate. In some variations, forming the carbon fiber sole plate can further include placing one or more shaped layers into a sole plate mold, where at least one of the one or more shaped layers includes one or more sublayers including carbon fibers, glass fibers, glass fleece prepreg, and/or resin. In some variations, forming the carbon fiber sole plate can further include molding the carbon fiber sole plate by applying at least one of heat or pressure to the one or more shaped layers within the sole plate mold, and removing the carbon fiber sole plate from the sole plate mold. In some variations, the one or more shaped layers can include two or more shaped layers, and where forming the carbon fiber sole plate can further include applying, after placement of the two or more shaped layers into the sole plate mold, a vacuum to the two or more shaped layers to vacuum form the two or more shaped layers.

These and other objects, along with advantages and features of the embodiments of the present invention herein disclosed, will become more apparent through reference to the following description, the accompanying drawings, and the claims. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of embodiments of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:

FIG. 1A is a cross sectional view of a sole of an article of footwear, in accordance with some embodiments of the present invention;

FIG. 1B is an exploded side perspective view of the sole of FIG. 1A, in accordance with some embodiments of the present invention;

FIG. 1C is a bottom view of a sole of an article of footwear, in accordance with some embodiments of the present invention;

FIG. 1D is a right side view of the sole of FIG. 1A, in accordance with some embodiments of the present invention;

FIG. 1E is a cross-sectional view taken along lines A-A of FIG. 1C, in accordance with some embodiments of the present invention;

FIG. 1F is a cross-sectional view taken along lines B-B of FIG. 1C, in accordance with some embodiments of the present invention;

FIG. 1G is a cross-sectional view taken along lines C-C of FIG. 1C, in accordance with some embodiments of the present invention;

FIG. 1H is a cross-sectional view taken along lines D-D of FIG. 1C, in accordance with some embodiments of the present invention;

FIG. 1I is a cross-sectional view taken along lines E-E of FIG. 1C, in accordance with some embodiments of the present invention;

FIG. 1J is a cross-sectional view taken along lines F-F of FIG. 1C, in accordance with some embodiments of the present invention;

FIG. 1K is a cross-sectional view taken along lines G-G of FIG. 1C, in accordance with some embodiments of the present invention;

FIG. 2A is a top perspective view of a mounting receptacle, in accordance with some embodiments of the present invention;

FIG. 2B is a bottom perspective view of the mounting receptacle of FIG. 2A, in accordance with some embodiments of the present invention;

FIG. 2C is a bottom view of the mounting receptacle of FIG. 2A, in accordance with some embodiments of the present invention;

FIG. 2D is a cross-sectional view taken along lines A-A of FIG. 2C, in accordance with some embodiments of the present invention;

FIG. 3A is a top perspective view of a mounting receptacle, in accordance with some embodiments of the present invention;

FIG. 3B is a bottom perspective view of the mounting receptacle of FIG. 3A, in accordance with some embodiments of the present invention;

FIG. 3C is a bottom view of the mounting receptacle of FIG. 3A, in accordance with some embodiments of the present invention;

FIG. 3D is a cross-sectional view taken along lines A-A of FIG. 3C, in accordance with some embodiments of the present invention;

FIG. 4A is a cross sectional view of a sole of an article of footwear, in accordance with some embodiments of the present invention;

FIG. 4B is an exploded side perspective view of the sole of FIG. 4A, in accordance with some embodiments of the present invention;

FIG. 5A is a bottom perspective view of a mounting receptacle, in accordance with some embodiments of the present invention;

FIG. 5B is a top perspective view of the mounting receptacle of FIG. 5A, in accordance with some embodiments of the present invention;

FIG. 5C is a bottom view of the mounting receptacle of FIG. 5A, in accordance with some embodiments of the present invention;

FIG. 5D is a cross-sectional view taken along lines B-B of FIG. 5C, in accordance with some embodiments of the present invention;

FIG. 6A is a cross sectional view of a carbon fiber sole plate prior to assembly, in accordance with some embodiments of the present invention;

FIG. 6B is a cross sectional view of the carbon fiber sole plate of FIG. 6A after assembly and prior to molding, in accordance with some embodiments of the present invention;

FIG. 6C is a cross sectional view of a fabricated carbon fiber sole plate after molding, in accordance with some embodiments of the present invention;

FIG. 6D is a cross sectional view of a fabricated carbon fiber sole plate after molding, in accordance with some embodiments of the present invention;

FIG. 7 is a flowchart of a method of manufacturing a sole of an article of footwear, in accordance with some embodiments of the present invention;

FIG. 8A is an exploded side perspective view of a sole of an article of footwear, in accordance with some embodiments of the present invention;

FIG. 8B is bottom view of the sole of FIG. 8A, in accordance with some embodiments of the present invention;

FIG. 9 is an exploded side perspective view of a sole of an article of footwear, in accordance with some embodiments of the present invention; and

FIG. 10 is a flowchart of a method of manufacturing a sole of an article of footwear, in accordance with some embodiments of the present invention.

DETAILED DESCRIPTION

Sole Having Carbon Fiber Sole Plate with Integrated Mounting Receptacles for an Article of Footwear and Manufacturing Thereof

Referring to FIGS. 1A-1K, a sole 100 can include a midsole 110 and a carbon fiber sole plate 140 having one or more integrated mounting receptacles 160 for one or more detachable primary traction elements 180. The midsole 110 can include a top midsole surface 112 and a bottom midsole surface 122 opposite the top midsole surface 112. The midsole 110 can include a sidewall 118 extending between the top midsole surface 112 and the bottom midsole surface 122. In some variations, referring to FIG. 1D, the midsole 110 can include a forefoot midsole area 124, a midfoot midsole area 126, and a heel midsole area 128. The bottom midsole surface 122 or a portion thereof may be configured to contact a ground, e.g., track, surface. As an example, only the midfoot midsole area 126 and the heel midsole area 128 may be configured to contact a ground surface. As another example, only the heel midsole area 128 may be configured to contact a ground surface. In some variations, referring to FIG. 1C, the bottom midsole surface 122 can define a number of traction elements 125, such as one or more traction elements 125, at the midfoot midsole area 126 and/or the heel midsole area 128.

In some variations, the midsole 110 can be made of an elastomer material, such as ethylene-vinyl acetate (EVA), thermoplastic polyurethane (TPU), and thermoplastic elastomer (TPE) (e.g., thermoplastic polyester elastomer (TPEE, TPE-E), and/or polyether block amide (PEBA)). For example, the elastomer material can be Pebax® polymer produced by ARKEMA. In some variations, the midsole 110 can be manufactured using injection molding techniques and/or compression molding techniques.

In some embodiments, the top midsole surface 112 can be connected to a shoe upper (not shown), thereby coupling the sole 100 to the shoe upper (such as by bonding, cementing, stitching, or any other appropriate method known in the art). The combination of the sole 100 and the shoe upper can form an article of footwear. As an example, the sole 100 and the upper material can form a track shoe with spikes for use in track and field sporting events.

In some embodiments, the sole 100 can include one or more outsole elements coupled to the bottom midsole surface 122. The outsole elements or a portion thereof may be configured to contact a ground, e.g., track, surface. The outsole elements may be coupled, e.g., adhered, to the bottom midsole surface 122 at the midfoot midsole area 126 and/or the heel midsole area 128. As an example, the outsole elements may be disposed on the bottom midsole surface 122 at the heel midsole area 128. The outsole elements may include a number of traction elements and may be made of rubber. The outsole element or elements may be of any appropriate size and shape, and have any appropriate tread pattern of arrangement of traction elements, for example, to provide the necessary traction properties while minimizing weight and manufacturing complexity.

In some embodiments, the bottom midsole surface 122 can define a number of indentations 130. For example, the bottom midsole surface 122 can define between 4 indentations 130 and 12 indentations 130, e.g., 6 indentations 130. The bottom midsole surface 122 can define the indentations 130 in the forefoot midsole area 124 of the midsole 110. The indentations 130 may have a diameter between 10 mm and 22 mm, e.g., 16 mm and a depth between 3 mm and 6.2 mm, e.g., 4.6 mm. The indentations 130 may be uniformly distributed and/or non-uniformly distributed on the bottom midsole surface 122. The indentations 130 may be substantially uniform.

In some embodiments, referring to FIGS. 1C, 1H, and 1I, the bottom midsole surface 122 can define a hollow channel 129. In some variations, the bottom midsole surface 122 can define the hollow channel in the midfoot midsole area 126 and the heel midsole area 128 of the midsole 110. As an example, the bottom midsole surface 122 can define the hollow channel 129 extending from the midfoot midsole area 126 to the heel midsole area 128 of the midsole 110. In some variations, an outsole disposed on the bottom midsole surface 122 at the heel midsole area 128 may be disposed about and adjacent to the hollow channel 129.

In some embodiments, referring to FIGS. 1A-1C, the carbon fiber sole plate 140 includes a top plate surface 142 and a bottom plate surface 152 opposite the top plate surface 142. The carbon fiber sole plate 140 can include a forefoot plate area 144, a midfoot plate area 146, and a heel plate area 148. When the carbon fiber sole plate 140 is integrated into an article of footwear, the forefoot plate area 144 may be adjacent to a wearer's forefoot, the midfoot plate area 146 may be adjacent to the wearer's midfoot, and the heel plate area 148 may be adjacent to a wearer's heel. The top plate surface 142 may be attached, e.g., adhered, to the bottom midsole surface 122 of the midsole 110. The bottom plate surface 152 or a portion thereof may be configured to contact a ground, e.g., track, surface. As an example, each of the forefoot plate area 144, the midfoot plate area 146, and the heel plate area 148 may be configured to contact a ground surface. As another example, only the forefoot plate area 144 and the midfoot plate area 146 may be configured to contact a ground surface. The midfoot plate area 146 can extend between the forefoot plate area 144 and the heel plate area 148.

In some variations, the bottom plate surface 152 can define a number of corrugations 156, e.g., ridges, extending along the midfoot plate area 146 and the heel plate area 148. The corrugations 156 may increase a stiffness and a rigidity of the carbon fiber sole plate 140 in the midfoot plate area 146 and the heel plate area 148, thereby further inhibiting flexure of the midfoot plate area 146 and the heel plate area 148 relative to the forefoot plate area 144 of the carbon fiber sole plate 140. In some variations, the hollow channel 129 of bottom midsole surface 122 can receive the midfoot plate area 146 and the heel plate area 148 of the carbon fiber sole plate 140. As an example, the top plate surface 142 at the midfoot plate area 146 and the heel plate area 148 of the carbon fiber sole plate 140 can be adhered to and received within the hollow channel 129 of the midsole 110.

In some embodiments, referring to FIGS. 1A, 1E, 1F, and 1J, the top plate surface 142 can define a number of hollow convex structures 150. For example, the top plate surface 142 can define between 4 hollow convex structures 150 and 12 hollow convex structures 150, e.g., 6 hollow convex structures 150. The top plate surface 142 can define the hollow convex structures 150 in the forefoot plate area 144. Each of the convex structures 150 can be sized and configured to be inserted into and received by a respective one of the indentations 130 in the midsole 110, such that each of the indentations 130 receives a respective one of the hollow convex structures 150. For example, a shape and size of the convex structures 150 may be complementary to a shape and size of the indentations 130. The convex structures 150 may have a diameter between 10 mm and 22 mm, e.g., 16 mm, and a depth, e.g., thickness, between 4 mm and 9 mm, e.g., 6.5 mm. The convex structures 150 may be uniformly distributed and/or non-uniformly distributed as defined by the top plate surface 142. The convex structures 150 may be substantially uniform and/or discrete.

In some embodiments, referring to FIGS. 1A, 1E, 1F, and 1J, a portion of the carbon fiber sole plate 140, such as the bottom plate surface 152, can define a number of cavities 154 in the forefoot plate area 144. In some variations, a sidewall 155 of each cavity 154 is formed by an inner surface of a respective one of the convex structures 150 defined by the top plate surface 142. The cavities 154 may have a size and shape defined by the dimensions of the mounting receptacles 160 disposed at least partially within the cavities 154. The number of cavities 154 may be uniformly distributed and/or non-uniformly distributed as defined by the bottom plate surface 152. The cavities 154 may be substantially uniform.

In some embodiments, referring to FIGS. 1A-1C, 1E, and 1J, the bottom plate surface 152 can define a number of secondary traction elements 190 in the forefoot plate area 144. The secondary traction elements 190 may be configured to contact and engage with a ground, e.g., track, surface, thereby providing enhanced traction for the sole 100 on the ground surface. The secondary traction elements 190 may be defined to surround the cavities 154 of the bottom plate surface 152. The secondary traction elements 190 may have a height between 1 mm and 3 mm, e.g., 2 mm, a width between 2 mm and 3 mm, and a length between 3 mm and 6 mm. In some variations, each the secondary traction elements 190 can include three or more tapered extensions forming a polyhedron or a portion thereof. As an example, each of the secondary traction elements 190 can include three tapered extensions forming a tetrahedron. The secondary traction elements 190 may be uniformly distributed and/or non-uniformly distributed as defined by the bottom plate surface 152. In some variations, the secondary traction elements 190 may have different sizes.

In some embodiments, the carbon fiber sole plate 140 can include one or more layers, e.g., shaped layers, of carbon fibers, glass fibers, glass fleece, prepreg (composite material made from pre-impregnated fibers and a partially cured polymer matrix), and/or resin. In some variations, the prepreg material may include carbon fibers and/or glass fibers that are pre-impregnated with resin (e.g., resin fibers). In some variations, the resin of the carbon fiber sole plate may be a thermoset resin and/or a thermoformable plastic resin. As an example, when the carbon fiber sole plate 140 includes thermoset resin (e.g., a thermoset epoxy resin), the carbon fiber sole plate may be initially heated and molded and may not be remolded after the initial molding. As another example, when the carbon fiber sole plate 140 includes thermoformable (also referred to as thermoplastic) resin and does not include thermoset resin, the carbon fiber sole plate 140 may be initially molded and may be remolded after the initial molding. The carbon fiber sole plate 140 may have a variable thickness based on a placement of layers of materials across different layers of the carbon fiber sole plate. As an example, the carbon fiber sole plate 140 may have a thickness between 1 mm and 1.3 mm.

In some embodiments, fibers included in a layer, e.g., shaped layer, of the carbon fiber sole plate 140 may be oriented in any suitable orientation and may have any suitable density based on desired structural and performance characteristics of the carbon fiber sole plate 140. As an example, the fibers of each layer may be oriented in any direction between 0 and 180 degrees to the longitudinal axis of the article of footwear, and the orientation of any successive layer is not limited by the orientation of the previous one with respect to one another. A distribution of fibers in an individual layer and successive layers of the carbon fiber sole plate may enable highly adaptable and customizable distribution of fibers over any portion of the carbon fiber sole plate 140, which may be adapted to beneficially support any required combination of stiffness, flexibility, protection, and other performance characteristics. In some variations, layers, e.g., shaped layers, of the carbon fiber sole plate 140 may be fabricated by weaving, knitting, tailored fiber placement (TFP), and/or any other suitable technique for fabricating one or more layers of fibers.

In some embodiments, the sole 100 can include a number of mounting receptacles 160 disposed at least partially within the cavities 154 of the carbon fiber sole plate 140. Each of the mounting receptacles 160 can be configured to engage with the sidewall 155 of a respective one of the cavities 154. Each mounting receptacle 160 can include a first fastener 164 of a number of first fasteners 164. In some variations, the first fastener 164 may be a female thread defined on an inner surface of the mounting receptacle 160 having the first fastener 164. In some variations, the mounting receptacles 160 may be made of metal (e.g., aluminum). In some variations, each mounting receptacle 160 can include an outer surface configured to engage with the sidewall 155 of the cavity 154 in which such a mounting receptacle is disposed. The sidewall 155 of each cavity 154 can retain the mounting receptacle 160 disposed within the cavity and can couple the mounting receptacle 160 to the bottom plate surface 152. In some variations, a first fastener 164 of a mounting receptacle 160 may be configured to receive a portion of a primary traction element 180. As an example, a first fastener 164 of a mounting receptacle 160 may be configured to receive a second fastener 184 of a primary traction element 180, with at least a portion of the primary traction element 180 being inserted into and received by an opening to the inner surface of mounting receptacle 160. In some variations, each mounting receptacle 160 can include a bottom surface, with the bottom surface or a portion thereof surrounding the opening to the inner surface and being configured to contact a ground, e.g., track, surface. A bottom surface of a mounting receptacle 160 may be positioned adjacent to a bottom plate surface 152 of the carbon fiber sole plate 140, such that both the bottom surface of the mounting receptacle 160 and the bottom plate surface 152 are configured to contact a ground, e.g., track, surface.

In some embodiments, one or more types of the mounting receptacles 160 can be included in the sole 100. Types of mounting receptacles included in the sole 100 may be selected based on a desired weight of the sole 100. In some variations, types of mounting receptacles can include toothed mounting receptacles having outer surfaces defining a number of teeth and knurled mounting receptacles having outer surfaces each defining a knurled pattern. The knurled pattern can include straight, diagonal, and/or diamond-shaped ridges and/or raised elements.

Referring to FIGS. 2A-2D, types of mounting receptacles may include first toothed mounting receptacles 260 having outer surfaces 262 defining a number of teeth 264. A first toothed mounting receptacle 260 can include an inner surface defining a female thread as a first fastener 266. The first toothed mounting receptacle 260 can define an opening 267 to the inner surface. In some variations, the outer surface 262 of the mounting receptacle 260 can define an indentation 268 on a top of the mounting receptacle 260 opposite the first fastener 266. In some variations, the mounting receptacle 260 can include a bottom surface 269, with the bottom surface or a portion thereof surrounding the opening 267 to the inner surface and being configured to contact a ground, e.g., track, surface. Referring to FIGS. 3A-3D, types of mounting receptacles may include second toothed mounting receptacles 360 having outer surfaces 362 defining a number of teeth 364. A toothed mounting receptacle 360 can include an inner surface defining a female thread as a first fastener 366. The toothed mounting receptacle 360 can define an opening 367 to the inner surface. In some variations, varying from the top of the mounting receptacle 260, the outer surface 362 of the mounting receptacle 360 can define a planar surface 368 on a top of the mounting receptacle 360 opposite the first fastener 366. In some variations, the mounting receptacle 360 can include a bottom surface 369, with the bottom surface or a portion thereof surrounding the opening 367 to the inner surface and being configured contact a ground, e.g., track, surface. Referring to FIG. 1A and also to FIGS. 2A-2D and 3A-3D, the outer surface of each mounting receptacle can define a number of teeth, with the teeth engaging with and contacting the sidewall 155 of the cavity 154 in which such a mounting receptacle is disposed. In some variations, the teeth of the outer surface of the mounting receptacle can prevent rotation and translation of the mounting receptacle within the cavity 154 in which the mounting receptacle is disposed.

In some embodiments, portions of the mounting receptacles 160 disposed within the cavities 154 of the carbon fiber sole plate 140 may be flush with the bottom plate surface 152 of the carbon fiber sole plate 140. As an example, openings to first fasteners 164 of the mounting receptacles 160 and/or bottom surfaces of the mounting receptacles 160 may be flush (e.g., coplanar) with the bottom plate surface 152 of the carbon fiber sole plate 140, such that the openings and/or bottom surfaces are aligned with the bottom plate surface and do not extend beyond the bottom plate surface away from the sole 100. In some cases, areas of the bottom plate surface 152 of the carbon fiber sole plate 140 surrounding the mounting receptacles 160 may be flush, with portions of the mounting receptacles. As an example, areas of the bottom plate surface 152 of the carbon fiber sole plate 140 surrounding the openings to the first fasteners 164 of the mounting receptacles 160 and/or bottom surfaces of the mounting receptacles 160 may be flush (e.g., coplanar) with such openings and/or bottom surfaces. Referring to FIG. 6C, an area 652 of the bottom plate surface 632 of a carbon fiber sole plate surrounding the mounting receptacle 160 may be flush with a portion of the mounting receptacle 160. In some embodiments, portions of the mounting receptacles 160 disposed within the cavities 154 of the carbon fiber sole plate 140 may be substantially flush with the bottom plate surface 152 of the carbon fiber sole plate 140, such that any difference between the bottom plate surface 152 and the bottom surface of the mounting receptacle 160 is insufficient to reduce the contact area between the bottom plate surface 152 and a ground surface during a ground contact stride of a running motion. In some variations, a portion of a mounting receptacle 160 disposed within a cavity 154 of the carbon fiber sole plate 140 may be substantially flush with the bottom plate surface 152 of the carbon fiber sole plate 140, e.g., such that there is less than a 2 mm difference in height, or preferably less than a 1 mm difference in height, between adjacent surfaces of the portion of a mounting receptacle 160 and the bottom plate surface 152 of the carbon fiber sole plate 140 surrounding the portion of the mounting receptacle 160.

In some embodiments, the bottom plate surface 152 can define a number of second convex structures in the forefoot plate area opposite the convex structures 150 defined by the top plate surface 142. Referring to FIG. 6D, a second convex structure 654 of the bottom plate surface 642 of a carbon fiber sole plate can surround the mounting receptacle 160. The second convex structures 654 may have a diameter between 10 mm and 22 mm, e.g., 16 mm, and a thickness T₆₅₄ between 0 mm and 3 mm. The mounting receptacles 160 may be disposed in the second convex structures 654, with each second convex structure 654 being defined by the bottom plate surface 642 opposite a respective convex structure 150 defined by the top plate surface 142.

In some embodiments, referring to FIGS. 1A, 1F, and 1J, the sole 100 can include a number of primary traction elements 180. Each of the primary traction elements 180 can be configured to detachably couple to a respective mounting receptacle 160. Each primary traction element 180 can include a projection 188 of a number of projections 188 and a second fastener 184 of a number of second fasteners 184. Some non-limiting examples of projections 188 are spikes, cleats, studs, gripping elements, and tread patterns. In some variations, each of the primary traction elements 180 can be configured to detachably couple to a respective mounting receptacle 160 via engagement between the first and second fasteners 164, 184. In some variations, the second fastener 184 may be a male thread and may have a height between 3 mm and 5 mm, e.g., 4 mm. As an example, when the first fasteners 164 of the mounting receptacles 160 are female threads and the second fasteners 184 of the primary traction elements 180 are male threads, a primary traction element 180 may be detachably coupled to a mounting receptacle 160 by rotating and threading the male thread of the primary traction element 180 into the female thread of a respective mounting receptacle 160. In some variations, the projections 188, e.g., spikes, may be made of metal (e.g., steel). The projections 188 may be configured to contact and engage with a ground, e.g., track, surface, thereby providing enhanced traction for the sole 100 on the ground surface. The projections 188 can be configured to protrude from the mounting receptacles 160 to which the primary traction elements 180 are coupled away from the bottom plate surface 152. When the projections 188 are spikes, the spikes may have a height between 6 mm and 8 mm, e.g., 7 mm and a diameter between 6 mm and 8 mm, e.g., 7 mm at a base of the spike connecting the spike to the second fastener 184 of the primary traction element 180. In some variations, when the projections 188 are spikes, each of the spikes can include a cone or a portion thereof. In some variations, each of the spikes can include three or more tapered extensions forming a polyhedron or a portion thereof.

In some embodiments, the traction elements included on the sole 100 can be included on the carbon fiber sole plate 140, the midsole 110, and/or an outsole (if present). Such traction elements may be customized to provide improved grip during a specific athletic activity or activities.

Customization of the traction elements can be based on a number of physical, performance (e.g., kinematic performance), and/or user preference characteristics associated with an individual or group of individuals. Accordingly, the performance requirements of a specific athletic activity can be taken into account when customizing footwear for a specific athlete or subset of athletes. As an example, traction requirements for a runner (such as a track runner, a road runner, or a cross-country runner) may be different depending on whether the runner is a sprinter or long distance runner, and/or whether the runner requires the traction elements on the sole (e.g., sole 100) of the footwear to account for running around a corner (e.g., on a standard indoor or outdoor athletic track), or whether the running is to be carried out in a predominantly straight line (e.g., during road racing or jogging). Customization of footwear may also depend upon the weather and underfoot conditions in which the athlete is performing with, for example, different traction requirements being needed for wet/dry conditions and/or soft/firm underfoot conditions. In addition, different sports may require different shapes, sizes, and/or configurations of traction elements (e.g., spikes, cleats, studs, gripping elements, and/or tread patterns) with, for example, traction elements for track and field, soccer, American football, field hockey, baseball, lacrosse, etc. all requiring different traction element-types and configurations, and with different positions within each of these sports potentially requiring different performance features from the traction elements.

Other athletic activities for which footwear can be customized include activities with significant cutting-type motions (e.g., baseball, softball, soccer, American football, field hockey, rugby, etc.) where an individual's technique and physical characteristics can vary greatly from person to person, and where specifically customized traction elements can greatly improve the individuals performance of the athletic motion. Other activities such as jumping, crouching, kicking, throwing, turning, spinning, etc. can also be accounted for in creating traction elements that enhance or support the unique combination of performance characteristics of a specific athlete and/or activity. Additional descriptions of traction elements and customization thereof can be found in at least U.S. Pat. No. 10,279,581, the entire contents of which are incorporated herein by reference.

In some embodiments, the traction elements of the sole 100 or a portion thereof are shaped, oriented, and arranged to provide optimized performance characteristics for the shoe incorporating the sole based on specific design considerations. The traction elements of the sole or a portion thereof may be symmetrically, or asymmetrically configured, as required. In addition, the traction elements may be of varying height and size or all of the same height and/or size and may taper at any appropriate angle. While embodiments of a sole (e.g., sole 100) are shown and described as including a number of indentations, a number of corrugations, a number of hollow convex structures, a number of cavities, a number of mounting receptacles, a number of second convex structures, a number of primary traction elements, and/or a number of secondary traction elements, some embodiments of the sole may include only one of any of such elements.

Referring to FIGS. 4A-4B, in an embodiment, rather than the mounting receptacles discussed above with a knurled or teethed outer sidewall surface, a sole 400 can incorporate mounting receptacles 460 with flanges on the outer sidewall to provide an alternative mechanism for fixedly holding the mounting receptacles within the cavity in the convex structures defined by the carbon fiber plate. As discussed above, the sole 400 can include a midsole 410, a carbon fiber sole plate 440, a number of mounting receptacles 460, and a number of primary traction elements 480. Referring also to FIGS. 5A-5D, flanged mounting receptacles 560 may have outer surfaces 562 defining one or more flanges 564. A flanged mounting receptacle 560 can include an inner surface defining a female thread as a first fastener 566. The flanged mounting receptacle 560 can define an opening 567 to the inner surface. In some variations, the outer surface 562 of each mounting receptacle 560 can define one or more, e.g., four, flanges 564, with the flanges 564 engaging with and contacting the sidewall of the cavity in which each mounting receptacle 560 is disposed. In some variations, the flange(s) 564 of the outer surface 562 of the mounting receptacle 560 can prevent rotation and translation of the mounting receptacle 560 within the cavity in which the mounting receptacle 560 is disposed. In some variations, the mounting receptacle 560 can include a bottom surface 569, with the bottom surface or a portion thereof surrounding the opening 567 to the inner surface and being configured contact a ground, e.g., track, surface.

In some embodiments, a carbon fiber sole plate of a sole may be formed and fabricated as a part of a method for manufacturing the sole of the article of footwear, e.g., track shoe with spikes. In some variations, a carbon fiber sole plate (e.g., the carbon fiber sole plate 140) can be formed and fabricated from one or more shaped layers and the mounting receptacles described herein. The shaped layers can include one or more layers of carbon fibers, glass fibers, glass fleece, prepreg, and/or resin. In some variations, one or more of the shaped layers may be die cut and shaped from sheets of carbon fibers, glass fibers, glass fleece, prepreg, and/or resin. The shaped layers may have a number of different shapes and sizes based on a function and placement of the different shaped layers within the finished carbon fiber sole plate. To fabricate the carbon fiber sole plate from the shaped layers and the mounting receptacles, the shaped layers and the mounting receptacles may be placed into a sole plate mold, heated, and molded therein. In some variations, the sole plate mold may have a shape complementary to a desired shape of the finished carbon fiber sole plate. The carbon fiber sole plate may be formed by the placement and molding of the shaped layers and mounting receptacles within the sole plate mold. Molding of the shaped layers and mounting receptacles within the sole plate mold may include applying heat and pressure to the shaped layers and mounting receptacles. In some variations, the primary traction elements may be detachably coupled to the mounting receptacles before, during, or after fabrication of the carbon fiber sole plate from the shaped layers and mounting receptacles.

In some embodiments, referring to FIGS. 6A and 6B, a number of shaped layers may be placed into a sole plate mold with a number of mounting receptacles. The shaped layers may include one or more first shaped layers 602, one or more reinforcement shaped layers 612, one or more second shaped layers, and one or more covering shaped layers 622. Referring to FIG. 6A, a layup 600 of a carbon fiber sole plate prior to assembly and placement of the shaped layers, the mounting receptacle 160, and the primary traction element 180 into a sole plate mold is illustrated. The first shaped layer 602 may define at least one opening 604 configured to receive the mounting receptacle 160 and/or the primary traction element 180. Based on the positioning of the mounting receptacle 160 relative to the opening 604, a fastener of the mounting receptacle 160 may be accessible via the opening 604 after fabrication, e.g., molding, of the carbon fiber sole plate. In some variations, layup 600 may include two reinforcement shaped layers 612 each including an opening 614 configured to receive the mounting receptacle 160 and/or the primary traction element 180. In some variations, the layup 600 can include at least one covering shaped layer 622 configured to cover the mounting receptacle 160.

In some embodiments, referring also to FIG. 6B, a layup 601 of a carbon fiber sole plate after assembly and placement of the shaped layers, the mounting receptacle 160, and the primary traction element 180 into a sole plate mold and before molding of the carbon fiber sole plate is illustrated. The opening 604 of the first shaped layer 602 may receive the mounting receptacle 160 and/or the primary traction element 180. The openings 614 of each reinforcement shaped layer 612 may receive the mounting receptacle 160 and/or the primary traction element 180. The covering shaped layer 622 can cover the mounting receptacle 160. After placement of the shaped layers, the mounting receptacle 160, and the primary traction element 180 into a sole plate mold to form the layup 601, heat and pressure can be applied to the layup 601 to form the carbon fiber sole plate, thereby causing the shaped layers to conform around the mounting receptacle 160 and conform to a shape of the sole plate mold. After application of heat and pressure to the layup 601, the layup 601 may be formed into the carbon fiber sole plate. Referring to FIGS. 6C and 6D, after application of heat and pressure to the layup 601 within the sole plate mold, the carbon fiber sole plate formed therefrom may have a bottom plate surface 632 or a bottom plate surface 642 based on a shape of the sole plate mold.

In some embodiments, referring to FIG. 7, a method 700 for fabrication of a sole having a carbon fiber sole plate including a number of integrated mounting receptacles can include one or more of the following steps. At step 702, a carbon fiber sole plate can be formed. The carbon fiber sole plate can include a top plate surface, a bottom plate surface configured to contact a ground surface, a forefoot plate area, a midfoot plate area, a heel plate area, and a mounting receptacle. In some variations, the carbon fiber sole plate can include a number of mounting receptacles, with each mounting receptacle including a first fastener of a plurality of first fasteners.

In some embodiments, the fabrication of a carbon fiber sole plate of step 702 can include one or more of the following steps. The description of the steps refers to shaped layers. Each shaped layer can be a layer of material that may include multiple sublayers; one or more of the shaped layers are approximately the size and shape of the finished carbon fiber sole plate. At step 702a, one or more first shaped layers may be placed into a sole plate mold. As an example, the first shaped layers may include (i) a first shaped layer including two sublayers of carbon fiber prepreg, a sublayer of resin film, and a sublayer of glass fleece, (ii) a second shaped layer including two sublayers of a carbon fiber prepreg, and (iii) a third shaped layer including two sublayers of the carbon fiber prepreg. Each of the first shaped layers placed into the sole plate mold can have an outer edge, with the outer edge of each shaped layer aligning with the outer edges of the other shaped layers within the sole plate mold. Each of the first shaped layers placed into the sole plate mold can define a number of openings, with the openings of each shaped layer aligning with the openings of the other shaped layers. One or more of the first shaped layers can be approximately the size and shape of the finished carbon fiber sole plate. Between and/or after placement of different first shaped layers into the sole plate mold, the first shaped layers placed and positioned on the mold may be placed under vacuum (e.g., for 10 seconds) to vacuum form the first shaped layers. In some variations, vacuum forming the first shaped layers can remove air between each of the first shaped layers and/or cause the first shaped layers placed into and within the sole plate mold to conform to a shape of the mold.

At step 702b, a number of mounting receptacles may be placed into the sole plate mold on top of the first shaped layers and adjacent to and/or on top of the openings of the first shaped layers. In some variations, placing the mounting receptacles into the sole plate mold on top of the first shaped layers and adjacent to and/or on top of the openings of the first shaped layers can include placing the mounting receptacles into the sole plate mold into the openings of the first shaped layers. Each of the openings may receive a respective mounting receptacle of the mounting receptacles. Based on the positioning of the mounting receptacles relative to the openings of the first shaped layers, the fasteners of the mounting receptacles may be accessible via the openings after fabrication of the carbon fiber sole plate.

At step 702c, one or more reinforcement shaped layers may be placed into the sole plate mold on top of the first shaped layers and on top of and/or adjacent to the mounting receptacles. Each reinforcement shaped layer may have one or more sublayers, e.g., five sublayers, of, e.g., the carbon fiber prepreg. In some variations, the one or more reinforcement shaped layers may combine to have seventeen sublayers of carbon fiber prepreg. In some variations, at least one of the reinforcement shaped layers can have a disc shape or an elliptical shape with an opening. In some variations, when the reinforcement shaped layers are placed into the sole plate mold, the reinforcement shaped layers may at least partially surround each of the mounting receptacles. The reinforcement shaped layers may be configured to provide support to the mounting receptacles within the finished carbon fiber sole plate. In some variations, the reinforcement shaped layers may form at least a portion of the convex structures defined by the top sole plate of the finished carbon fiber sole plate. In some variations, the reinforcement shaped layers may form at least a portion of the inner surfaces of the convex structures.

In some variations, one or more of the reinforcement shaped layers may be placed into the sole plate mold on top of the first shaped layers and under the mounting receptacles. In some variations, one or more of the reinforcement shaped layers may be placed into the sole plate mold on top of the first shaped layers before placement of the mounting receptacles, such that one or more of the mounting receptacles are placed on top of the reinforcement shaped layers. In some variations, one or more of the reinforcement shaped layers may be placed on top of, under, and/or adjacent to the mounting receptacles before placement of the mounting receptacles into the sole plate mold, e.g., on top of the first shaped layers.

At step 702d, one or more second shaped layers may be placed into a sole plate mold on top of the first shaped layers, the mounting receptacles, and the reinforcement shaped layers. The second shaped layers may have, e.g., a first shaped layer with two sublayers of the carbon fiber prepreg, and a second shaped layer having a sublayer of glass fabric. One or more of the second shaped layers can be approximately the size and shape of the finished carbon fiber sole plate. When placed into the sole plate mold, the second shaped layers may cover the first shaped layers, the mounting receptacles, and/or the reinforcement shaped layers. Each of the second shaped layers placed into the sole plate mold can have an outer edge, with the outer edge of each shaped layer aligning with the outer edges of the other shaped layers within the sole plate mold. In some variations, between and/or after placement of different second shaped layers into the sole plate mold, the second shaped layers placed and positioned on the mold may be placed under vacuum to vacuum form the second shaped layers. In some variations, vacuum forming the second shaped layers can remove air between each of first shaped layers, the second shaped layers, the mounting receptacles, and/or the reinforcement shaped layers. In some variations, vacuum forming the second shaped layers can cause the second shaped layers that are placed into and within the sole plate mold to conform to a shape of the mold.

At step 702e, one or more covering shaped layers may be placed into the sole plate mold on top of the first shaped layers, the mounting receptacles, the reinforcement shaped layers, and the second shaped layers. The covering shaped layers may include, e.g., a first shaped layer with four sublayers of the carbon fiber prepreg and a second shaped layer with a first sublayer of glass fabric and a second sublayer of carbon fiber prepreg. In some variations, the covering shaped layers may at least partially cover each of the mounting receptacles and may form at least a portion of the top sole plate within the finished carbon fiber sole plate. For example, the covering shaped layers may entirely cover the mounting receptacles, such that the mounting receptacles are not accessible by the top sole plate of the finished carbon fiber sole plate. In some variations, the covering shaped layers may form at least a portion of the convex structures defined by the top sole plate of the finished carbon fiber sole plate. In some variations, the covering shaped layers may form at least a portion of the inner surfaces the convex structures. In some variations, between and/or after placement of different covering shaped layers into the sole plate mold, the covering shaped layers placed and positioned on the mold may be placed under vacuum to vacuum form the covering shaped layers. In some variations, vacuum forming the covering shaped layers can remove air between each of first shaped layers, the second shaped layers, the mounting receptacles, the reinforcement shaped layers, and/or the covering shaped layers. In some variations, vacuum forming the covering shaped layers can cause the covering shaped layers that are placed into and within the sole plate mold to conform to a shape of the mold.

At step 702f, a removeable protective layer may be placed into the sole plate mold on top of the first shaped layers, the mounting receptacles, the reinforcement shaped layers, the second shaped layers, and the covering shaped layers. When placed into the sole plate mold, the removeable protective cover may cover the first shaped layers, the mounting receptacles, the reinforcement shaped layers, the second shaped layers, and the covering shaped layers. In some variations, the removeable protective layer may be configured to protect the shaped layers during heating and molding of the shaped layers and the mounting receptacles within the sole plate mold. In some variations, the removeable protective layer may be a polyester (PET) film. The removeable protective layer may removably adhere to the shaped layers.

At step 702g, the finished carbon fiber sole plate can be molded from the shaped layers and mounting receptacles. To mold the finished carbon fiber sole plate from the shaped layers and mounting receptacles, heat can be applied to the shaped layers and mounting receptacles within the sole plate mold, thereby softening (e.g., melting) a thermoset resin and/or a thermoformable resin included in one or more of the shaped layers. By heating and softening the resin, the shaped layers can conform around the mounting receptacles and to the shape of the sole plate mold. In some cases, during molding of the finished carbon fiber sole plate from the shaped layers and mounting receptacles, at least one of pressure or heat can be applied to the shaped layers and mounting receptacles included in the sole plate mold. In some cases, both pressure and heat can be applied to the shaped layers and mounting receptacles included in the sole plate mold. By heating and softening the resin and/or applying pressure to the shaped layers and mounting receptacles, the shaped layers can conform around the mounting receptacles and conform to the shape of the sole plate mold. In some cases, the molding of the finished carbon fiber sole plate from the shaped layers and mounting receptacles can last from 1000 seconds to 2600 seconds, e.g., 1800 seconds. The resin included in the shaped layers may be heated to a temperature greater than or equal to a softening point of the resin. As an example, the resin may be heated to a temperature between 130 degrees Celsius (C) and 160 degrees C., e.g., between 138 degrees C. and 142 degrees C. In some cases, a pressure applied to the shaped layers and mounting receptacles can be between 70 kilograms (kg) per cubic meter and 90 kg per cubic meter, e.g., 80 kg per cubic meter.

At step 702h, the finished carbon fiber sole plate can be removed from the sole plate mold and the removeable protective layer can be removed from the finished carbon fiber sole plate. In some cases, after the finished carbon fiber sole plate is removed from the sole plate mold, the finished carbon fiber sole plate can be cleaned and/or sanded to remove excess material.

In some embodiments, at step 704, after fabrication of the finished carbon fiber sole plate, the carbon fiber sole plate may be coupled, e.g., attached, to the midsole to fabricate a sole of an article of footwear (e.g., a track shoe with spikes), with the midsole including a top midsole surface and a bottom midsole surface. To couple the carbon fiber sole plate to the midsole, a primer may be applied to the top plate surface of the carbon fiber sole plate and to the bottom midsole surface of the midsole. The primer may be applied to an entirety of the top plate surface and to the forefoot midsole area and the hollow channel of the bottom midsole surface of the midsole. After applying the primer to each of the top plate surface and bottom midsole surface, an adhesive may be applied to each of the top plate surface of the carbon fiber sole plate and to the bottom midsole surface of the midsole. As an example, the adhesive may be applied to the entirety of the top plate surface and to the forefoot midsole area and the hollow channel on the bottom midsole surface of the midsole. After applying the adhesive to each of the top plate surface and bottom midsole surface of the midsole, the top plate surface of the carbon fiber sole plate may be placed onto the bottom midsole surface, such that the forefoot midsole area is aligned with the forefoot plate area and the hollow channel receives the midfoot plate area and the heel plate area of the carbon fiber sole plate. After the top plate surface of the carbon fiber sole plate is placed onto the bottom midsole surface of the midsole, the carbon fiber sole plate and the midsole may be pressed together. In some variations, the carbon fiber sole plate and the midsole may be pressed together manually (e.g., by a manufacturing technician) and/or by a press machine that applies pressure to the top midsole surface and/or to the bottom plate surface. After the top plate surface of the carbon fiber sole plate and the bottom midsole surface of the midsole are pressed together, the carbon fiber sole plate and the midsole may be coupled, e.g., joined, together to form a finished sole for an article of footwear, e.g., track shoe with spikes.

In some embodiments, at step 706, a detachable traction element can be detachably coupled a mounting receptacle of the carbon fiber sole plate. In some variations, a number of detachable traction elements can be detachably coupled the mounting receptacles of the carbon fiber sole plate. In some variations, the primary traction elements may be detachably coupled to the mounting receptacles before, during, or after fabrication of the carbon fiber sole plate.

In some embodiments, the top midsole surface of the sole can be connected to a shoe upper, thereby coupling the sole to the shoe upper to form an article of footwear. The finished article of footwear can include a shoe upper, midsole, and carbon fiber sole plate having a number of mounting receptacles.

Sole Having Carbon Fiber Sole Plate and Holding Plate with Integrated Mounting Receptacles for an Article of Footwear and Manufacturing Thereof

Referring to FIGS. 8A and 8B, a sole 800, can include a midsole 810, a carbon fiber sole plate 840, and a holding plate 870 having one or more integrated mounting receptacles 860 for one or more detachable primary traction elements. In some embodiments, a bottom midsole surface of the midsole can define a number of indentations 830. For example, the bottom midsole surface can define between 4 indentations and 12 indentations, e.g., 5 indentations. The bottom midsole surface can define the indentations in a forefoot midsole area of the midsole 810. The indentations 830 may have a diameter between 10 mm and 22 mm, e.g., 16 mm and a depth between 3 mm and 6.2 mm, e.g., 4.6 mm. The indentations 830 may be uniformly distributed and/or non-uniformly distributed on the bottom midsole surface. The indentations may be substantially uniform.

In some embodiments, referring to FIGS. 8A and 8B, the bottom midsole surface can define a recess 820. In some variations, the bottom midsole surface can define the recess 820 in a forefoot midsole area of the midsole. As an example, the bottom midsole surface can define the recess 820 extending along a periphery of the forefoot midsole area of the midsole 810. In some variations, the recess 820 can form between 20 percent and 60 percent, e.g., 40 percent, of the forefoot midsole area on the bottom midsole surface. In some variations, the indentations 830 defined by the bottom midsole surface can be disposed within the recess 820 in the forefoot midsole area. As an example, the indentations 830 in the forefoot midsole area can be disposed entirely within the recess 820 defined by the bottom midsole surface. In some variations, the recess 820 may have a depth between 2 mm and 5.5 mm and a width between 12 mm and 26 mm. In some variations, a size and shape of the recess 820 and the indentations 830 can be complementary to a shape and size of a holding plate 870.

In some embodiments, the sole can include the carbon fiber sole plate 840 including a top plate surface and a bottom plate surface opposite the top plate surface. The carbon fiber sole plate can include a forefoot plate area, a midfoot plate area, and a heel plate area. The top plate surface may be attached, e.g., adhered, to the bottom midsole surface of the midsole 810 and to a bottom holding surface of the holding plate 870.

In some embodiments, the carbon fiber sole plate 840 can define a number of openings 858 extending between the top plate surface and the bottom plate surface. The carbon fiber sole plate 840 can define the openings 858 in the forefoot plate area. Each of the openings can be sized and configured to receive a primary traction element, such that a projection of such primary traction element can extend through the opening 858. As an example, shapes and sizes of the openings 858 may be complementary to a shape and size of the primary traction elements or portions thereof. In some variations, each of the openings 858 can be sized and configured to receive a mounting receptacle 860 or portion thereof, such that the mounting receptacle 860 or portion thereof can at least partially extend through the opening 858. For example, shapes and sizes of the openings 858 may be complementary to a shape and size of the mounting receptacles 860 or portions thereof. The openings may have a diameter between 6 mm and 17 mm. The openings 858 may be uniformly distributed and/or non-uniformly distributed as defined by the carbon fiber sole plate 840. The openings 858 may be substantially uniform and/or discrete. Positions of the opening 858 as defined by the carbon fiber sole plate 840 may correspond to the positions of the mounting receptacles 860 on the holding plate 870.

In some embodiments, the bottom plate surface of the carbon fiber sole plate 840 can define a number of secondary traction elements 890 in the forefoot plate area. The secondary traction elements 890 may be configured to contact and engage with a ground, e.g., track, surface, thereby providing enhanced traction for the sole 800 on the ground surface. The secondary traction elements 890 may be defined to surround the openings 858 of the bottom plate surface.

In some embodiments, the sole can include the holding plate 870 including a top holding surface and a bottom holding surface opposite the top holding surface. In some variations, the holding plate 870 can be disposed between the bottom midsole surface of the midsole and the top plate surface of the carbon fiber sole plate 840. As an example, the top holding surface may be attached, e.g., adhered, to the bottom midsole surface of the midsole 810 and a bottom holding surface may be attached, e.g., adhered, to a top plate surface of the carbon fiber sole plate 840. In some variations, the recess 820 of the bottom midsole surface can receive the top holding surface of the holding plate 870. As an example, the top holding surface of the holding plate 870 can be adhered to and received within the recess 820 defined by the forefoot midsole area of the midsole 810. In some variations, when the holding plate 870 is attached to the bottom midsole surface of the midsole 810, the holding plate 870 or a portion thereof may be flush with the bottom midsole surface. As an example, when the holding plate 870 is attached to the bottom midsole surface of the midsole 810, the bottom holding surface or portion thereof of the holding plate 870 may be flush (e.g., coplanar) with the bottom midsole surface.

In some embodiments, the top holding surface of the holding plate 870 can define a number of hollow convex structures 850. Each of the convex structures 850 can be sized and configured to be inserted into and received by a respective one of the indentations 830 in the midsole 810, such that each of the indentations 830 receives a respective one of the hollow convex structures 850. As an example, a shape and size of the convex structures 850 may be complementary to a shape and size of the indentations 830. The convex structures 850 may have a diameter between 10 mm and 22 mm, e.g., 16 mm, and a depth between 4 mm and 9 mm, e.g., 6.5 mm. The convex structures 850 may be uniformly distributed and/or non-uniformly distributed as defined by the top holding surface of the holding plate 870. The convex structures 850 may be substantially uniform, and/or discrete.

In some embodiments, a portion of the holding plate 870, such as the bottom holding surface, can define a number of cavities. In some variations, a sidewall of each cavity is formed by an inner surface of a respective one of the convex structures 850 defined by the top holding surface. The cavities may have a size and shape defined by the dimensions of mounting receptacles 860 disposed at least partially within the cavities. The number of cavities may be uniformly distributed and/or non-uniformly distributed as defined by the bottom plate surface. The cavities may be substantially uniform.

In some embodiments, the holding plate 870 can be made of an elastomer material such as TPU. For example, the elastomer material can be Pebax® polymer produced by ARKEMA. In some variations, the holding plate 870 may be fabricated using injection molding techniques. The holding plate 870 may have a uniform thickness or a variable thickness. As an example, the holding plate 870 may have a thickness between 2 mm and 5.5 mm. In some variations, a thickness of the holding plate 870 may be complementary to a depth of the recess 820. While the holding plate 870 is shown and described as having unitary construction, in some variations, the holding plate 870 may have two or more separate holding plate sections.

In some embodiments, the sole 800 can include a number of mounting receptacles 860 disposed at least partially within the cavities of the holding plate 870. In some variations, each of the mounting receptacles 860 can be configured to engage with the sidewall of a respective one of the cavities. Each mounting receptacle 860 can include a first fastener of a number of first fasteners. In some variations, the first fastener may be a female thread. In some variations, the mounting receptacles 860 may be made of metal (e.g., aluminum). In some variations, each mounting receptacle 860 can include an outer surface configured to engage with the sidewall of the cavity in which such mounting receptacle 860 is disposed. The sidewall of each cavity can retain the mounting receptacle 860 disposed within the cavity and can couple the mounting receptacle 860 to the bottom holding surface. In some variations, each of the mounting receptacles 860 can be adhered to the sidewall of a respective one of the cavities.

In some embodiments, portions of the mounting receptacles 860 disposed within the cavities of the holding plate 870 may be flush with the bottom holding surface of the holding plate 870. As an example, openings to first fasteners of the mounting receptacles 860 and/or bottom surfaces of the mounting receptacles 860 may be flush (e.g., coplanar) with the bottom holding surface of the holding plate 870, such that the openings and/or bottom surfaces are aligned with the bottom plate surface and do not extend beyond the bottom plate surface away from the sole 800. In some cases, areas of the bottom holding surface of the holding plate 870 surrounding the mounting receptacles may be flush with portions of the mounting receptacles 860. As an example, areas of the bottom holding surface surrounding the openings to the first fasteners of the mounting receptacles 860 and/or bottom surfaces of the mounting receptacles 860 may be flush (e.g., coplanar) with such openings and/or bottom surfaces. In some cases, areas of the bottom plate surface of the carbon fiber sole plate 840 surrounding the mounting receptacles 860 and/or areas of the bottom holding surface may be flush with portions of the mounting receptacles and/or areas. As an example, areas of the bottom plate surface of the carbon fiber sole plate 840 surrounding the openings to the first fasteners of the mounting receptacles 860, bottom surfaces of the mounting receptacles 860, and/or areas of the bottom holding surface may be flush (e.g., coplanar) with such openings, bottom surfaces, and/or areas.

In some embodiments, portions of the mounting receptacles 860 disposed within the cavities of the holding plate 870 may be substantially flush with the bottom holding surface of the holding plate 870 and/or the bottom plate surface of the carbon fiber sole plate 840, such that any difference between the bottom plate surface, the bottom holding surface, and the bottom surface of the mounting receptacle 860 is insufficient to reduce the contact area between the bottom plate surface and a ground surface during a ground contact stride of a running motion. In some variations, a portion of a mounting receptacle 860 disposed within a cavity of the holding plate 870 may be substantially flush with the bottom holding surface of the holding plate 870 and/or the bottom plate surface of the carbon fiber sole plate 840, such that there is less than a 2 mm difference in height, or preferably less than a 1 mm difference in height, between adjacent surfaces of the portion of a mounting receptacle and the bottom holding surface of the holding plate 870 and/or the bottom plate surface of the carbon fiber sole plate 840 surrounding the portion of the mounting receptacle.

In some embodiments, the sole 800 can include a number of primary traction elements. Each of the primary traction elements can be configured to detachably couple to a respective mounting receptacle 860. While embodiments of a sole (e.g., sole 800) are shown and described as including a number of indentations, a number of openings, a number of hollow convex structures, a number of cavities, a number of mounting receptacles, a number of primary traction elements, and/or a number of secondary traction elements, some embodiments of the sole may include only one of any of such elements.

Referring to FIG. 9, a sole 900 can include a midsole 910, a carbon fiber sole plate 940, and a holding plate 970 having one or more integrated mounting receptacles 960 for one or more detachable primary traction elements. In some embodiments, a bottom midsole surface of the midsole 910 can define a recess 920. In some variations, the bottom midsole surface can define a recess 920 in a forefoot midsole area of the midsole. As an example, the bottom midsole surface can define the recess 920 extending along a periphery of the forefoot midsole area of the midsole 910. In some variations, the recess 920 can form between 20 percent and 60 percent, e.g., 40 percent, of the forefoot midsole area on the bottom midsole surface. In some variations, a size and shape of the recess 920 can be complementary to a shape and size of a holding plate 970.

In some embodiments, the sole can include the carbon fiber sole plate 940 including a top plate surface and a bottom plate surface opposite the top plate surface. The carbon fiber sole plate 940 can include a forefoot plate area, a midfoot plate area, and a heel plate area. The top plate surface may be attached, e.g., adhered, to the bottom midsole surface of the midsole 910 and to a bottom holding surface of the holding plate 970.

In some embodiments, the carbon fiber sole plate 940 can define a number of openings 958 extending between the top plate surface and the bottom plate surface. The carbon fiber sole plate can define the openings 958 in the forefoot plate area. Each of the openings can be sized and configured to receive a primary traction element, such that a projection of such primary traction element can extend through the opening 958. As an example, shapes and sizes of the openings 958 may be complementary to a shape and size of the primary traction elements or portions thereof. In some variations, each of the openings 958 can be sized and configured to receive a convex structure 950 or portion thereof of a holding plate, such that the convex structure 950 or portion thereof can extend through the opening. For example, shapes and sizes of the openings may be complementary to a shape and size of the convex structures 950 or portions thereof.

In some embodiments, the sole 900 can include the holding plate 970 including a top holding surface and a bottom holding surface opposite the top holding surface. In some variations, the recess 920 of the bottom midsole surface can receive the top holding surface of the holding plate 970. As an example, the top holding surface of the holding plate 970 can be adhered to and received within the recess 920 in the forefoot midsole area of the midsole 910. In some variations, when the holding plate 970 is attached to the bottom midsole surface of the midsole 910, the holding plate or a portion thereof may be flush with the bottom midsole surface. As an example, when the holding plate 970 is attached to the bottom midsole surface of the midsole 910, the bottom holding surface or portion thereof of the holding plate 970 may be flush (e.g., coplanar) with the bottom midsole surface.

In some embodiments, the bottom holding surface of the holding plate 970 can define a number of hollow convex structures 950. Each of the convex structures 950 can be sized and configured to be inserted into and received by a respective one of the openings 958 of the carbon fiber sole plate 940, such that each of the openings 958 receives a respective one of the hollow convex structures 950. For example, a shape and size of the convex structures 950 may be complementary to a shape and size of the openings 958. The convex structures 950 may have a diameter between 10 mm and 22 mm, e.g., 16 mm, and a depth between 4 mm and 9 mm, e.g., 6.5 mm. The convex structures 950 may be uniformly distributed and/or non-uniformly distributed as defined by the bottom holding surface of the holding plate 970. The convex structures 950 may be substantially uniform and/or discrete. In some variations, when the top plate surface of the carbon fiber sole plate 940 is attached to the bottom holding surface of the holding plate 970, portions of the convex structures 950 extending through the openings 958 may be flush with the bottom plate surface, such that such portions of the convex structures 950 are aligned with the bottom plate surface and do not extend beyond the bottom plate surface away from the sole 900.

In some embodiments, a portion of the holding plate 970, such as the bottom holding surface, can define a number of cavities. In some variations, a sidewall of each cavity is formed by an inner surface of a respective one of the convex structures defined by the bottom holding surface. The cavities may have a size and shape defined by the dimensions of mounting receptacles 960 disposed at least partially within the cavities. The number of cavities may be uniformly distributed and/or non-uniformly distributed as defined by the bottom plate surface. The cavities may be substantially uniform.

In some embodiments, the sole 900 can include a number of mounting receptacles 960 disposed at least partially within the cavities of the holding plate 970. In some variations, each of the mounting receptacles can be configured to engage with the sidewall of a respective one of the cavities. Each mounting receptacle 960 can include a first fastener of a number of first fasteners.

In some embodiments, portions of the mounting receptacles 960 disposed within the cavities of the holding plate 970 may be flush with the bottom holding surface of the holding plate 970. As an example, openings to first fasteners of the mounting receptacles 960 and/or bottom surfaces of the mounting receptacles 960 may be flush with the bottom holding surface of the holding plate 970, such that the openings and/or bottom surfaces are aligned with the bottom plate surface and do not extend beyond the bottom plate surface away from the sole 900. In some cases, areas of the bottom holding surface of the holding plate 970 surrounding the mounting receptacles 960 may be planar, e.g., flush, with the mounting receptacles 960. As an example, areas (e.g., convex structures 950) of the bottom holding surface surrounding the openings to the first fasteners of the mounting receptacles 960 and/or bottom surfaces of the mounting receptacles 960 may be flush (e.g., coplanar) with such openings and/or bottom surfaces. In some cases, areas of the bottom plate surface of the carbon fiber sole plate 940 surrounding the mounting receptacles 960 and/or areas of the bottom holding surface may be flush with portions of the mounting receptacles and/or areas. As an example, areas of the bottom plate surface of the carbon fiber sole plate 940 surrounding the openings to the first fasteners of the mounting receptacles 960, bottom surfaces of the mounting receptacles 960, and/or areas of the bottom holding surface may be flush (e.g. coplanar) with such openings, bottom surfaces, and/or areas.

In some embodiments, the mounting receptacles 960 disposed within the cavities of the holding plate 970 may be substantially flush with the bottom holding surface of the holding plate 970 and/or the bottom plate surface of the carbon fiber sole plate 940, such that any difference between the bottom plate surface, the bottom holding surface, and the bottom surface of the mounting receptacle 960 is insufficient to reduce the contact area between the bottom plate surface and a ground surface during a ground contact stride of a running motion. In some variations, a portion of a mounting receptacle 960 disposed within a cavity of the holding plate 970 may be substantially flush with the bottom holding surface of the holding plate 970 and/or the bottom plate surface of the carbon fiber sole plate 940 such that there is less than a 2 mm difference in height, or preferably less than a 1 mm difference in height, between adjacent surfaces of the portion of a mounting receptacle and the bottom holding surface of the holding plate 970 and/or the bottom plate surface of the carbon fiber sole plate 940 surrounding the portion of the mounting receptacle.

In some embodiments, the sole 900 can include a number of primary traction elements. Each of the primary traction elements can be configured to detachably couple to a respective mounting receptacle 960. While embodiments of a sole (e.g., sole 900) are shown and described as including a number of openings, a number of hollow convex structures, a number of cavities, a number of mounting receptacles, and/or a number of primary traction elements, some embodiments of the sole may include only one of any of such elements.

In some embodiments, a holding plate of a sole may be formed and fabricated as a part of a method for manufacturing the sole of the article of footwear, e.g., track shoe with spikes. In some embodiments, referring to FIG. 10, a method 1000 for fabrication of a sole having a carbon fiber sole plate and a holding plate including a number of integrated mounting receptacles can include one or more of the following steps. In some variations, at step 1002, the holding plate can be formed and fabricated by injection molding of an elastomer material in a mold. The holding plate can include a top holding surface, a bottom holding surface, and a mounting receptacle. In some variations, the holding plate can include a number of mounting receptacles. In some variations, a number of mounting receptacles may be placed into the mold prior to injection of the elastomer material, such that the mounting receptacles are integrated into and disposed within the holding plate. In some variations, a holding plate shell of the holding plate may be injection molded to include a number of cavities, where the mounting receptacles are placed into to the cavities and coupled to the holding plate shell to form the holding plate. As an example, mounting receptacles may be placed into and adhered to the cavities via an adhesive applied to sidewalls of the cavities and/or to outer surfaces of the mounting receptacles. As another example, mounting receptacles may be placed into and coupled to the cavities via engagement between the sidewalls of the cavities and the outer surfaces of the mounting receptacles, where the mounting receptacles are “press-fit” into the cavities. In some variations, the primary traction elements may be detachably coupled to the mounting receptacles before, during, or after fabrication of the holding plate.

In some embodiments, at step 1004, after fabrication of the holding plate, the holding plate may be coupled, e.g., attached, to the midsole. The midsole can include a top midsole surface and a bottom midsole surface. The bottom midsole surface can define a recess in a forefoot midsole area. To couple the holding plate to the midsole, a primer may be applied to the top holding surface of the holding plate and to the bottom midsole surface of the midsole. As an example, the primer may be applied to an entirety of the top holding surface and to the recess defined by the bottom midsole surface of the midsole. After applying the primer to each of the top holding surface and the recess, an adhesive may be applied to each of the top holding surface and to the recess. As an example, the adhesive may be applied to the entirety of the top holding surface and to the recess. After applying the adhesive to each of the top holding surface and to the recess, the top holding surface of the holding plate may be placed onto the recess of the bottom midsole surface, such that the recess receives the top holding surface of the holding plate. After, the top holding surface of the holding plate is placed onto the recess of the bottom midsole surface, the holding plate and the midsole may be pressed together. In some variations, the holding plate and the midsole may be pressed together manually (e.g., by a manufacturing technician) and/or by a press machine that applies pressure to the top midsole surface and/or to the bottom holding surface. After the holding plate and the midsole are pressed together, the holding plate and the midsole may be coupled, e.g., joined, together.

In some variations, at step 1006, the carbon fiber sole plate of a sole can be formed and fabricated from one or more shaped layers. The carbon fiber sole plate can include a top plate surface, a bottom plate surface configured to contact a ground surface, a forefoot plate area, a midfoot plate area, and a heel plate area. The shaped layers can include one or more layers of carbon fibers, glass fibers, prepreg, and/or resin. In some variations, the shaped layers may be die cut and shaped from sheets of carbon fibers, glass fibers, glass fleece, prepreg, and/or resin. The shaped layers may have a number of different shapes and sizes based on a function and placement of the different shaped layers within the finished carbon fiber sole plate. To fabricate the carbon fiber sole plate from the shaped layers and the mounting receptacles, the shaped layers and the mounting receptacles may be placed into a sole plate mold, heated, and molded therein. In some variations, the sole plate mold may have a shape complementary to a desired shape of the finished carbon fiber sole plate. Molding of the shaped layers within the sole plate mold may include applying heat and pressure to the shaped layers.

In some embodiments, at step 1008, after the holding plate is coupled to the midsole, the carbon fiber sole plate may be coupled, e.g., attached, to the midsole and the holding plate to fabricate a sole of an article of footwear (e.g., a track shoe with spikes). To couple the carbon fiber sole plate to the midsole and the holding plate, a primer may be applied to the top plate surface of the carbon fiber sole plate, the bottom midsole surface of the midsole, and the bottom holding surface of the holding plate. As an example, the primer may be applied to an entirety of the top plate surface and to each of the forefoot midsole area of the bottom midsole surface, the hollow channel of the bottom midsole surface, and the bottom holding surface of the holding plate. After applying the primer to each of the top plate surface, the bottom midsole surface, and the bottom holding surface, an adhesive may be applied to each of the top plate surface of the carbon fiber sole plate, the bottom midsole surface of the midsole, and the bottom holding surface of the holding plate. As an example, the adhesive may be applied to the entirety of the top plate surface and to each of the forefoot midsole area of the bottom midsole surface, the hollow channel of the bottom midsole surface, and the bottom holding surface of the holding plate. After application of the adhesive to each of the top plate surface, bottom midsole surface of the midsole, and bottom holding surface of the holding plate, the top plate surface of the carbon fiber sole plate may be placed onto the bottom midsole surface and bottom holding surface, such that the forefoot midsole area is aligned with the forefoot plate area and the hollow channel receives the midfoot plate area and the heel plate area of the carbon fiber sole plate.

In some embodiments, after the top plate surface of the carbon fiber sole plate is placed onto the bottom midsole surface of the midsole and the bottom holding surface of the holding plate, the carbon fiber sole plate and the midsole may be pressed together. In some variations, the carbon fiber sole plate and the midsole may be pressed together manually (e.g., by a manufacturing technician) and/or by a press machine that applies pressure to the top midsole surface and/or to the bottom plate surface. After the top plate surface of the carbon fiber sole plate and the bottom midsole surface of the midsole are pressed together, the carbon fiber sole plate, the holding plate, and the midsole may be coupled, e.g., joined, together to form a finished sole for an article of footwear, e.g., track shoe with spikes.

In some embodiments, at step 1010, a detachable traction element can be detachably coupled a mounting receptacle of the holding plate. In some variations, a number of detachable traction elements can be detachably coupled the mounting receptacles of the holding plate. In some variations, the primary traction elements may be detachably coupled to the mounting receptacles before, during, or after fabrication of the holding plate.

In some embodiments, the top midsole surface of the sole can be connected to a shoe upper, thereby coupling the sole to the shoe upper to form an article of footwear. The finished article of footwear can include a shoe upper, midsole, holding plate, and carbon fiber sole plate having mounting receptacles.

In some embodiments of the invention, the sole may further comprise a second sole plate (e.g., a carbon fiber sole plate), that may be positioned above the midsole between the midsole and the shoe upper, be partially embedded within the midsole (between an upper surface (e.g., top midsole surface) and lower surface (e.g., bottom midsole surface) of the midsole), or be positioned below the midsole between the lower surface of the midsole and the upper surface of the first sole plate having the mounting receptacles. The second sole plate may be configured to provide additional performance benefits to the shoe sole, such as additional stiffness and energy return. In certain embodiments of the invention, the second sole plate may include a first region having a first position with respect to the midsole (e.g., a first region at least partially embedded within the midsole between a top midsole surface and a bottom midsole surface) and a second region having a second position with respect to the midsole (e.g., above the top surface of the midsole or below the bottom surface of the midsole). In various embodiments, the second sole plate may have any number of regions having any appropriate relationship to the midsole, with transition regions between a first region and second region. In one embodiment, at least a first region of the second sole plate may contact (either in bonded, or otherwise fixed, contact, or in unbonded contact) at least a first region of the first sole plate having the mounting receptacles.

In another embodiment, the second sole plate is separated from the first sole plate throughout the entire sole unit (e.g., midsole).

Embodiments of a sole may include one or more features and/or characteristics of any of the soles (e.g., the soles 100, 400, 800, and/or 900) as described herein. The terms and expressions employed herein are used as terms and expressions of description and not of limitation and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described or portions thereof. In addition, having described certain embodiments of the invention, it will be apparent to those of ordinary skill in the art that other embodiments incorporating the concepts disclosed herein may be used without departing from the spirit and scope of the invention. The structural features and functions of the various embodiments may be arranged in various combinations and permutations, and all are considered to be within the scope of the disclosed embodiments of the invention. Unless otherwise necessitated, recited steps in the various methods may be performed in any order and certain steps may be performed substantially simultaneously. Accordingly, the described embodiments are to be considered in all respects as only illustrative and not restrictive. Furthermore, the configurations described herein are intended as illustrative and in no way limiting. Similarly, although physical explanations have been provided for explanatory purposes, there is no intent to be bound by any particular theory or mechanism, or to limit the claims in accordance therewith.