Footwear sole structure and upper with an embedded plate

Abstract

A sole structure includes an outsole defining an inner outsole surface and an outer outsole surface opposite the inner outer surface. The inner outsole surface is spaced apart from the outer outsole surface along a first direction. The sole structure further includes a midsole disposed on the outsole and a footwear plate is directly coupled to the midsole. The footwear plate includes a composite material and includes a first plate portion, a second plate portion is connected to the first plate portion, and a third plate portion is connected to the second plate portion. The second plate portion is connected between the first plate portion and the third plate portion. The second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along the first direction.

What is claimed is: 
     
         1 . A sole structure, comprising:
 an outsole defining an inner outsole surface and an outer outsole surface opposite the inner outsole surface, and the inner outsole surface is spaced apart from the outer outsole surface along a first direction;
 a midsole disposed on the outsole; 
 a footwear plate is directly coupled to the midsole, wherein the footwear plate includes a composite material and includes a first plate portion, a second plate portion is connected to the first plate portion, and a third plate portion is connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion; and 
   wherein the second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along the first direction to enhance stability of the sole structure while minimizing energy loss as the sole structure contacts a ground surface.   
     
     
         2 . The sole structure of  claim 1 , wherein the midsole includes a midsole material, the composite material has a first stiffness, the midsole material has a second stiffness, and the first stiffness is greater than the second stiffness. 
     
     
         3 . The sole structure of  claim 1 , wherein the midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface, the midsole defines a midsole thru-hole extending from the inner midsole surface to the outer midsole surface of the midsole, the second plate portion is disposed inside the midsole thru-hole of the midsole, the first plate portion is disposed at a forefoot region of the sole structure, the third plate portion is disposed at a heel region of the sole structure, and the second plate portion is disposed in a midfoot region of the sole structure, the third plate portion is disposed on top of the midsole, the second plate portion is disposed between the inner midsole surface and the outer midsole surface of the midsole, and the midsole thru-hole is obliquely angled relative to the inner midsole surface and the outer midsole surface, the first plate portion is spaced apart from the second plate portion along a second direction, the second direction is perpendicular to the first direction, and the outsole is elongated along the second direction. 
     
     
         4 . The sole structure of  claim 3 , wherein the midsole defines a midsole longitudinal recess in communication with the midsole thru-hole, the midsole longitudinal recess is adjacent the outsole, the midsole longitudinal recess is disposed in the forefoot region of the sole structure, and the first plate portion is at least partially disposed in the midsole longitudinal recess to maximize energy return during toe off. 
     
     
         5 . The sole structure of  claim 4 , wherein the outsole defines an inner outsole surface and an outer outsole surface opposite the inner outsole surface the third plate portion is in direct contact with the inner outsole surface of the outsole, the midsole longitudinal recess is elongated along the second direction, and the second direction is perpendicular to the first direction. 
     
     
         6 . The sole structure of  claim 1 , wherein the midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface, the midsole defines a midsole opening extending from the inner midsole surface into the midsole, the midsole opening does not extend through an entirety of a thickness of the midsole, and the second plate portion is disposed inside the midsole opening of the midsole, and the third plate portion is disposed on top of the inner midsole surface at a heel region of the sole structure. 
     
     
         7 . The sole structure of  claim 6 , wherein the first plate portion is disposed at a forefoot region of the sole structure, the first plate portion is disposed inside the midsole, and the first plate portion is closer to the inner midsole surface than to the outer midsole surface of the midsole. 
     
     
         8 . The sole structure of  claim 1 , wherein the midsole is configured as a drop-in midsole, the midsole is entirely disposed inside an interior void of an upper, the third plate portion is disposed inside the midsole, and the first plate portion is disposed inside the outsole. 
     
     
         9 . The sole structure of  claim 8 , wherein the midsole is only disposed at a heel region of the sole structure. 
     
     
         10 . The sole structure of  claim 8 , wherein the midsole extends through a heel region, a midfoot region, and a forefoot region of the sole structure. 
     
     
         11 . The sole structure of  claim 8 , wherein the midsole includes a first midsole part and a second midsole part spaced apart from each other along a longitudinal axis of the sole structure to define a gap therebetween, and the gap receives the second plate portion of the footwear plate. 
     
     
         12 . An article of footwear, comprising:
 an upper defining an interior void and an ankle opening in communication with the interior void;   a sole structure coupled to the upper, wherein the sole structure includes a forefoot region, a midfoot region, and a heel region, the midfoot region is disposed between the forefoot region and the heel region, and the sole structure includes:
 an outsole defining an inner outsole surface and an outer outsole surface opposite the inner outsole surface, and the inner outsole surface is spaced apart from the outer outsole surface along a first direction; 
 a midsole disposed on the outsole; 
 a footwear plate is coupled to the midsole, wherein the footwear plate includes a composite material and includes a first plate portion, a second plate portion directly connected to the first plate portion, and a third plate portion directly connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion; and 
   wherein the second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along the first direction to enhance stability of the sole structure while minimizing energy loss of the sole structure as the article of footwear contacts a ground surface.   
     
     
         13 . The article of footwear of  claim 12 , wherein the midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface, the inner midsole surface faces the upper, the outer midsole surface faces away from the upper, the midsole defines a midsole thru-hole extending from the inner midsole surface to the outer midsole surface of the midsole, the second plate portion is disposed inside the midsole thru-hole of the midsole, the first plate portion is disposed in the forefoot region of the sole structure, the third plate portion is disposed in the heel region of the sole structure, and the second plate portion is disposed in the midfoot region of the sole structure. 
     
     
         14 . The article of footwear of  claim 13 , wherein the third plate portion is disposed on top of the midsole, the second plate portion is disposed between the inner midsole surface and the outer midsole surface of the midsole, and the midsole thru-hole is obliquely angled relative to the inner midsole surface and the outer midsole surface. 
     
     
         15 . The article of footwear of  claim 14 , wherein the midsole defines a midsole longitudinal recess in communication with the midsole thru-hole, the midsole longitudinal recess is adjacent the outsole, the midsole longitudinal recess is disposed in the forefoot region of the sole structure, and the first plate portion is at least partially disposed in the midsole longitudinal recess to maximize energy return during toe off. 
     
     
         16 . The article of footwear of  claim 15 , wherein the outsole defines an inner outsole surface and an outer outsole surface opposite the inner outsole surface, the inner outsole surface faces the upper, the outer outsole surface faces away from the upper, the third plate portion is in direct contact with the inner outsole surface of the outsole, the midsole longitudinal recess is elongated along a second direction, and the second direction is perpendicular to the first direction. 
     
     
         17 . The article of footwear of  claim 12 , wherein the midsole defines an inner midsole surface and an outer midsole surface opposite the inner midsole surface, the inner midsole surface faces the upper, the outer midsole surface faces away from the upper, the midsole defines a midsole opening extending from the inner midsole surface into the midsole, the midsole opening does not extend through an entirety of a thickness of the midsole, and the second plate portion is disposed inside the midsole opening of the midsole, and the third plate portion is disposed on top of the inner midsole surface at the heel region of the sole structure. 
     
     
         18 . The article of footwear of  claim 17 , wherein the first plate portion is disposed at the forefoot region of the sole structure, the first plate portion is disposed inside the midsole, and the first plate portion is closer to the inner midsole surface than to the outer midsole surface of the midsole. 
     
     
         19 . The article of footwear of  claim 12 , wherein the midsole is configured as a drop-in midsole, the midsole is entirely disposed inside the interior void of the upper, the third plate portion is disposed inside the midsole, and the first plate portion is disposed inside the outsole. 
     
     
         20 . The article of footwear of  claim 19 , wherein the midsole is only disposed at the heel region of the sole structure. 
     
     
         21 . The article of footwear of  claim 19 , wherein the midsole extends through the heel region, the midfoot region, and the forefoot region. 
     
     
         22 . The article of footwear of  claim 19 , wherein the midsole includes a first midsole part and a second midsole part spaced apart from each other along a longitudinal axis of the sole structure to define a gap therebetween, and the gap receives the second plate portion of the footwear plate. 
     
     
         23 . A method of manufacturing an article of footwear, comprising:
 inserting a footwear plate through an opening of a midsole to directly couple the footwear plate to the midsole, wherein the footwear plate includes a composite material, the footwear plate includes a first plate portion, a second plate portion is connected to the first plate portion, and a third plate portion is connected to the second plate portion, and the second plate portion is connected between the first plate portion and the third plate portion, and the second plate portion is obliquely angled relative to the first plate portion and the third plate portion so that the first plate portion is spaced apart from the third plate portion along a first direction;   attaching the midsole to the outsole, wherein the outsole is elongated along a longitudinal axis, the first direction is perpendicular to the longitudinal axis, a sole structure includes the midsole and the outsole, the sole structure has a forefoot region, a heel region, and a midfoot region between the forefoot region and the heel region, and the opening of the midsole is disposed at the midfoot region; and   attaching an upper to the sole structure.   
     
     
         24 . The method of  claim 23 , wherein the opening of the midsole is a thru-hole extending along an entirety of a thickness of the midsole. 
     
     
         25 . The method of  claim 23 , wherein the opening of the midsole extends along a portion of a thickness of the midsole.