Golf shoe with non-removable cleat and associated methods of making the same

Abstract

Defined herein is a golf shoe that includes an outsole, and at least one cleat non-removably coupled to the outsole. The at least one cleat includes a hub and a plurality of flexible arms extending radially outward away from the hub. An undercut is defined between each of the plurality of flexible arms and the outsole.

What is claimed is: 
     
         1 . A golf shoe, comprising:
 an outsole; and   at least one cleat non-removably coupled to the outsole, the at least one cleat comprising a hub and a plurality of flexible arms extending radially outward away from the hub, wherein an undercut is defined between each of the plurality of flexible arms and the outsole.   
     
     
         2 . The golf shoe of  claim 1 , wherein each of the plurality of flexible arms extends downward away from the outsole and hub. 
     
     
         3 . The golf shoe of  claim 1 , wherein each of the plurality of flexible arms is flexible upwardly toward the outsole and undercut. 
     
     
         4 . The golf shoe of  claim 1 , wherein a first set of the plurality of arms have a first size and a second set of the plurality of arms have a second size bigger than the first size. 
     
     
         5 . The golf shoe of  claim 1 , wherein the undercut comprises a space directly between each of the plurality of flexible arms and the outsole. 
     
     
         6 . The golf shoe of  claim 1 , wherein the outsole and the at least one cleat form a one-piece monolithic construction. 
     
     
         7 . The golf shoe of  claim 1 , wherein the at least one cleat is formed integrally with the outsole. 
     
     
         8 . The golf shoe of  claim 1 , wherein the at least one cleat is injection molded onto the outsole. 
     
     
         9 . The golf shoe of  claim 1 , wherein the at least one cleat is made from the same material as the outsole. 
     
     
         10 . The golf shoe of  claim 1 , wherein the at least one cleat is made from a first material, and the outsole is made from a second material different than the first material. 
     
     
         11 . The golf shoe of  claim 1 , further comprising a plurality of cleats non-removably coupled to the outsole. 
     
     
         12 . A method of making a golf shoe, comprising:
 forming an outsole;   non-removably coupling at least one cleat to the outsole, the at least one cleat comprising a hub and a plurality of flexible arms extending radially outward away from the hub; and   forming an undercut between each of the plurality of flexible arms and the outsole.   
     
     
         13 . The method of  claim 12 , wherein non-removably coupling the at least one cleat to the outsole comprises injection molding the at least one cleat directly onto the outsole. 
     
     
         14 . The method of  claim 12 , wherein forming the outsole and non-removably coupling the at least one cleat to the outsole comprises injection molding the outsole and the at least one cleat together as a monolithic one-piece construction. 
     
     
         15 . The method of  claim 12 , further comprising providing a mold defining a cleat-shaped cavity for receiving an injection molding material, the cleat-shaped cavity having a shape corresponding with the at least one cleat, wherein the mold comprises at least two vertical portions defining a first portion of the cleat-shaped cavity, the at least two vertical portions being vertically movable relative to each other, and wherein the mold comprises at least one lateral portion defining a second portion of the cleat-shaped cavity, the at least one lateral portion being movable relative to the at least two vertical portions. 
     
     
         16 . The method of  claim 15 , wherein non-removably coupling the at least one cleat to the outsole comprises injecting the injection molding material into the cleat-shaped cavity, and forming the undercut comprises rotating the at least one lateral portion relative to the at least two vertical portions. 
     
     
         17 . The method of  claim 15 , wherein the mold comprises at least two lateral portions, and wherein non-removably coupling the at least one cleat to the outsole comprises injecting the injection molding material into the cleat-shaped cavity, and forming the undercut comprises laterally moving the at least two lateral portions apart from each other and relative to the at least two vertical portions. 
     
     
         18 . The method of  claim 15 , wherein one of the at least two vertical portions defines an outer surface portion of the cleat-shaped cavity, the outer surface portion of the cleat-shaped cavity defining outer surfaces of the at least one cleat, wherein the outer surfaces of the at least one cleat face away from the outsole. 
     
     
         19 . The method of  claim 15 , wherein the at least one lateral portion defines an inner surface portion of the cleat-shaped cavity, the inner surface portion of the cleat-shaped cavity defining inner surfaces of the at least one cleat, wherein the inner surfaces of the at least one cleat form part of the plurality of flexible arms and face toward the outsole. 
     
     
         20 . An outsole for an athletic shoe, comprising:
 a base coupleable to an upper of the athletic shoe; and   at least one cleat non-removably coupled to the base, the at least one cleat comprising a hub and a plurality of flexible arms extending radially outward away from the hub, wherein an undercut is defined between each of the plurality of flexible arms and the base.