Footwear with sole assembly having midsole plate and heel insert and associated methods

Abstract

Footwear sole assemblies including a midsole plate and a heel insert and associated methods are disclosed herein. In one embodiment, for example, a sole assembly includes an outsole coupled to a midsole plate. The midsole plate can include a first plate portion and a second plate portion spaced apart from one another to define a cavity at a heel portion of the midsole plate. The cavity can be configured to receive an insert. The second plate portion can be proximate to the outsole, and the first plate portion can be spaced apart from the outsole. The first plate portion can include an opening extending through the heel portion. The sole assembly can further include a midsole pad coupled to the midsole plate and configured to contact the insert via the opening.

1 . A footwear assembly system for use in manufacturing articles of footwear, comprising:
 a plurality of uppers, including a first upper and a second upper;   a plurality of midsole plates each having a midsole arch portion between a midsole forefoot portion and a midsole heel portion, each midsole plate having top and bottom plates in at least the midsole heel portion and being spaced apart from each other to define a cavity with open sides, the top and bottom plates being connected to each other at a forward end and diverging away from each other as the top and bottom plates extend rearwardly relative to the midsole arch portion, the top and bottom plates being configured to elastically move toward each other under compressive forces applied to the midsole plate during use of the footwear; and   a plurality of midsole inserts each having a shape corresponding to the shape of the cavity, the plurality of inserts including first and second inserts, the first insert having first absorptive and energy-return characteristics for a first range of activities that apply first compressive loads to the midsole plate, and the second insert having second absorptive and energy-return characteristics different than the first absorptive and energy-return characteristics and for a second range of activities that apply second compressive loads to the midsole plate, the first and second inserts being interchangeably positionable in the cavity of each midsole plate during manufacture of footwear designed for the first or second ranges of activities.   
     
     
         2 . The system of  claim 1  wherein each midsole plate has an aperture in the top plate in communication with the cavity, and further comprising a plurality of contoured top pads, each top pad having a protrusion sized and positioned to substantially fill the aperture in the top plate and to engage an insert in the cavity. 
     
     
         3 . The system of  claim 1 , further comprising a plurality of outsoles attachable to the midsole plates, wherein each outsole having an outsole forefoot portion with a toe end area and having an upper portion with a stepped configuration that provides a shoulder positioned rearward of the toe end area, and each midsole plate having a leading edge and being positionable on the upper portion of the outsole with the leading edge abutting the shoulder to position the midsole plate on the outsole. 
     
     
         4 . The system of  claim 1  wherein the shoulder of each outsole having a thickness substantially the same as a thickness of the shoulder to provide a smooth transition between the upper portion of the outsole and the forefoot portion of the midsole plate. 
     
     
         5 . The system of  claim 1  wherein each of the inserts have a wedge shape. 
     
     
         6 . The system of  claim 1  wherein each of the inserts have sidewalls extending between the top and bottom plates when the insert in positioned in the cavity, and the sidewalls are concave. 
     
     
         7 . The system of  claim 1  wherein the top and bottom plates of each midsole plate are integrally connected to each other rearward of the forefoot portion. 
     
     
         8 . The system of  claim 1  wherein the first insert has a cant configuration to reduce pronation or supination of a wearer's foot. 
     
     
         9 . The system of  claim 1  wherein the midsole plates each have a plurality of stiffening features positioned in at least one of the forefoot or arch portions. 
     
     
         10 . A sole assembly for footwear, comprising:
 an outsole;   a midsole plate coupled to the outsole, the midsole plate having a first plate portion and a second plate portion spaced apart from one another to define a cavity at a heel portion of the midsole plate, wherein the second plate portion is proximate to the outsole, the first plate portion is spaced apart from the outsole and includes an opening extending through the heel portion, and the cavity is configured to receive an insert; and   a midsole pad coupled to the midsole plate and configured to contact the insert via the opening in the first plate portion.   
     
     
         11 . The sole assembly of  claim 10 , further comprising the insert positioned in the cavity, and wherein the midsole pad has a projection extending through the opening and engaging a top surface of the insert. 
     
     
         12 . The sole assembly of  claim 10  wherein the opening in the heel portion has a tear-drop shape. 
     
     
         13 . The sole assembly of  claim 10  wherein the outsole has a forefoot portion with a toe end and an upper portion facing the midsole assembly, and the upper portion has a stepped configuration that provides a shoulder positioned rearward of the toe end, and the midsole plate has a leading edge abutting the shoulder to position the midsole plate on the outsole. 
     
     
         14 . The sole assembly of  claim 13  wherein the shoulder of each outsole having a thickness substantially the same as a thickness of the shoulder to provide a smooth transition between the upper portion of the outsole and the forefoot portion of the midsole plate. 
     
     
         15 . The sole assembly of  claim 10  wherein the cavity is open on medial and lateral sides and further comprising the insert positioned in the cavity, the insert having concave sidewalls extending between the top and bottom plates adjacent to the medial and lateral sides of the cavity. 
     
     
         16 . The sole assembly of  claim 10  wherein the first and second plate portions are integrally connected to each other rearward of a forefoot portion of the midsole plate. 
     
     
         17 . The sole assembly of  claim 10  wherein the midsole plate has a plurality of stiffening features positioned in at least one of a forefoot portion or an arch portion of the midsole plate. 
     
     
         18 . An article of footwear, comprising:
 an upper and a sole assembly connected to the upper, the sole assembly having a midsole assembly and an outsole connected to the midsole assembly opposite the upper;   the outsole comprising an outsole forefoot portion with a toe bumper, the outsole forefoot portion having an upper portion facing the midsole assembly, the upper portion having a stepped configuration that provides a shoulder positioned rearward of the toe bumper;   the midsole assembly being positioned atop the outsole and having a midsole arch portion between a midsole forefoot portion and a midsole heel portion, the midsole forefoot portion being supported by the upper portion of the outsole forefoot portion, the midsole forefoot portion having a leading edge that abuts the shoulder of the outsole's upper portion, wherein the leading edge has a thickness substantially the same as a thickness of the shoulder to provide a smooth transition between the upper portion of the outsole and the midsole forefoot portion;   the midsole assembly comprising a midsole plate and a midsole insert;   the midsole plate having top and bottom plates in at least the midsole heel portion and being spaced apart from each other to define a cavity, the top and bottom plates being connected to each other at a forward end and spaced apart from each other as the top and bottom plates extend rearwardly relative to the midsole arch portion, the top plate having an aperture therethrough in communication with the cavity;   the midsole insert being disposed in the cavity between the top and bottom plates, the midsole insert having a shape that corresponds to the cavity, the midsole insert having a bottom surface engaging the bottom plate and a top surface engaging the top plate, the midsole insert being made of a deformable material with selected absorption and energy-return characteristics; and   a contoured top pad disposed atop the midsole plate, the contoured top pad having a protrusion disposed in the aperture of the midsole top plate and in engagement with the midsole insert.   
     
     
         19 . The article of footwear of  claim 18  wherein the midsole insert is a first midsole insert having a first absorptive and energy-return characteristic selected for a first range of activities, and further comprising a second midsole insert having a second absorptive and energy-return characteristics different from the first absorptive and energy-return characteristics and selected for a second range of activities, wherein the first and second midsole inserts are interchangeably positionable in the cavity during manufacture of the article of footwear to provide the article of footwear designed for a respective one of the first and second range of activities. 
     
     
         20 . The article of footwear of  claim 18  wherein the insert has concave sidewalls adjacent to edge portions of the top and bottom plates.