Footwear Cleat with Cushioning

This application is a continuation-in-part of U. S. patent application, ser. no. 11/754,509, filed May 29, 2007, entitled "Removable Footwear Cleat with Cushioning", which is incorporated herein by reference. This application claims priority from U.S. provisional patent application, ser. no. 60/809,323, filed May 30, 2006, entitled "Removable Footwear Cleat with Cushioning," which is incorporated herein by reference. This application also claims priority from U.S. provisional patent application, ser. no. 60/823,396, filed August 24, 2006, also entitled "Removable Footwear Cleat with Cushioning," which is incorporated herein by reference. This application also claims priority from U.S. provisional patent application, ser. no. 61/119,976, filed December 4, 2008, entitled "Footwear Cleat with Cushioning," which is incorporated herein by reference.

Technical Field

The present invention relates to traction cleats or projections mounted in or on the bottom of footwear, in particular, on the bottom of athletic footwear.

Background

Athletic shoe cleats, in particular golf cleats, have been subject to changing designs in recent years, to attempt to provide users with a variety of advantages. For many years, a cleat took a simple form of a spike, usually made of metal, attached to the bottom of a shoe. Because such spikes could damage non-athletic surfaces and some athletic surfaces as well, variations have been made from the simple form. For example, UK Patent Application 2,098,457 to Perks discloses surrounding a spike element of a cleat with soft material, to decrease damage done to surfaces. Summary of the Invention

In an embodiment of the invention, a ground-engaging cleat for an article of footwear is provided. The cleat includes a base layer with a top portion and a bottom portion. The top portion of the base layer includes a shoe attachment element for securing the cleat to the footwear's outsole. A cushioning layer directly engages the bottom portion of the base layer. The bottom portion of the cushioning layer provides the sole attachment for the traction element layer to the base layer, forming a "sandwich." The durometer of the cushioning layer, traction element layer and base layers are selected so that the layers remain securely connected during ground engagement of the footwear. Each of the base, cushioning and traction element layers is adapted to provide friction with the ground when the cleat engages the ground. The cushioning layer affords resilient backing to the traction element layer, enhancing user comfort. The traction element layer provides a durable covering for at least a portion of the cushioning layer, extending the life of the cleat.

In specific embodiments of the invention, the ground-engaging cleat is non- removably molded into the outsole of the shoe or the cleat may be provided with a removable shoe attachment that inserts into a receptacle in the outsole of the shoe.

Brief Description of the Drawings

The foregoing features of the invention will be more readily understood by reference to the following detailed description, taken with reference to the accompanying drawings, in which:

Fig. 1 is an exploded view of a removable cleat for footwear, according to an embodiment of the invention;

Figs. 2A-2B include several additional views of the cleat of fig. 1;

Fig. 3 is a sectional view of a removable cleat for an alternative embodiment of the invention;

Fig. 4 is another sectional view of the cleat of fig. 3;

Fig. 5 shows the ground contacting face of the cleat of fig. 3;

Figs. 6A-6B illustrate an alternative embodiment of the invention that includes cushioning material embedded in traction elements; Figs. 6C-6D illustrate another embodiment of the invention that includes cushioning material embedded in traction elements;

Figs. 7 A shows a view of the ground-engaging face of a cleat with a debris skirt, in an embodiment of the invention; Fig. 7B shows a view from the shoe-attachment side of the cleat of fig. 7A;

Fig. 8 shows a cutaway view of a section of the cleat of fig. 7A;

Figs. 9A-9B illustrate the reaction of the debris skirt to pressure from the adjacent traction element for the cleat of fig. 7A;

Fig. 10 shows a cleat with a debris skirt that folds, according to an embodiment of the invention;

Fig. 11 shows a cutaway view of a section of the cleat of fig. 10;

Fig. 12A shows a cleat with a hollow cushioning layer supporting a traction element, according to an embodiment of the invention;

Fig. 12B shows a cutaway view of a section of the cleat of fig. 12A; Fig. 13 shows an exploded view of a cleat with a traction element with an integral mechanical coupler, according to an embodiment of the invention;

Fig. 14 shows a view of the cleat of fig. 13, assembled;

Fig. 15 shows the cleat of fig. 13 in a cutaway side view, assembled;

Fig. 16 shows a cleat with a rivet fastener holding folding traction elements to a cleat disc according to an embodiment of the invention;

Fig. 17 shows a procedure for assembling the cleat of fig. 16;

Fig. 18 shows an alternative approach to fastening folding traction elements to a cleat disc in an embodiment of the invention;

Fig. 19 shows a cross-sectional view of a non-removable cushion cleat for embedding in the outsole of a shoe, in an embodiment of the invention;

Fig. 20 shows the cleat of fig. 19 positioned for assembly in a shoe outsole;

Fig. 21 shows a cut-away view of the cleat of fig. 19 embedded in a shoe outsole;

Fig. 22 shows the outsole of a finished sport shoe with the cleats of fig. 19 embedded in the outsole; Fig. 23 shows the outsole of a sport shoe with cushion cleats embedded in the outsole according to an alternative embodiment of the invention; Fig. 24 is a cut-away side view of cushion cleats embedded in a shoe outsole using an injection molding process, in an embodiment of the invention;

Fig. 25 is a cut-away side view of cushion cleats embedded in a shoe outsole using another injection molding process, according to another embodiment of the invention; and Fig. 26A shows the outsole of a sport shoe with cushion cleat projections embedded in traction plates in the outsole, according to an alternative embodiment of the invention;

Fig. 26B is a cut-away side view of the outsole of the sport shoe of fig. 26A; and

Fig. 26C is a cut-away side view of the outsole of the sport shoe of fig. 26A using another injection molding process, according to another embodiment of the invention.

Detailed Description of Specific Embodiments

Definitions. As used in this description and the accompanying claims, the following terms shall have the meanings indicated, unless the context otherwise requires:

A "shoe" means any outer covering for a foot including, without limitation, athletic footwear, sandals, boots, and slippers.

A "disc" means any object with opposing, generally planar faces. A disc can include concave portions or convex portions or combinations of concave and convex portions. Discs are not limited to circular shapes but may be, for example, elliptical, triangular, rectangular, or even irregular shapes, etc. In various embodiments of the present invention, a removable footwear cleat comprises a shoe attachment portion, a cushioning layer directly engaging the shoe attachment portion and a traction element assembly, positioned on the cushioning layer. Thus, the cleat forms a "sandwich." The shoe attachment portion includes a disc with opposing faces. One face of the disc includes a shoe attachment element that removably attaches the cleat to a corresponding element (i.e., receptacle) in a shoe outsole. A second face of the disc supports the cushioning layer. When a user steps on a surface wearing a shoe outfitted with these cleats, the resilience (i.e., "give") of the cushioning layer at once both lessens the impact of the traction elements on the ground surface and lessens the reaction force on the user's foot, as transmitted through the shoe's outsole. The user's comfort is thereby enhanced. In an embodiment of the invention, as shown in the exploded view of fig. 1, a removable cleat 10 consists of a "sandwich" comprising a shoe attachment portion 20, a cushioning layer 30 and a traction element assembly 40. The shoe attachment portion 20 supports the cushioning layer 30. The traction element assembly 40 is installed on the surface (or in the surface) of the cushioning layer 30. Fig. 2 shows a plan view of the cleat of fig. 1 from the top, along with two sectional views.

Referring to fig. 1, the shoe attachment portion 20 of the cleat includes a disc 24 with opposing faces. A male shoe attachment element 22 is coupled to a first face of the disc 24. The shoe attachment element may be formed according to any design known in the art, such as MacNeill Engineering's Q-LOK™ system, which is described in U.S. patent no.

5,768,809, which patent is incorporated herein by reference. The second face 26 of the shoe attachment disc 24 includes two or more cleat wrench pin shafts 60, formed typically as hollow cylinders, extending away from the disc face 26. These shafts 60 allow a cleat wrench to attach temporarily to the cleat for removably attaching the cleat to a shoe outsole. The user inserts the prongs of a cleat wrench into the wrench pin shafts and applies torque to the wrench to rotate the cleat. Insertion of the shoe attachment element 22 into a matching receptacle (not shown) in the shoe outsole, followed by rotation of the cleat, attaches the cleat to the outsole. These wrench pin shafts extend through the cushioning layer of the cleat and through the traction element assembly to the surface of the ground-engaging face of the cleat. This construction avoids attaching the cleat wrench to either the traction element assembly or to the cushioning material. The former is likely to twist as torque is applied by the wrench while the latter is too soft to transfer torque to the shoe attachment element of the cleat effectively.

In some embodiments of the invention, the second face of the disc 26 (i.e. ground- facing face) includes one or more raised portions 61. This raised portion 61 is located below the ground-engaging surface of the cleat, when the cleat is complete. In preferred embodiments, this raised portion may be attached to the center of the ground-facing disc face 26. This raised portion can serve as a wear indicator. When the ground-engaging surface (i.e. traction element assembly 40) of the cleat has worn away sufficiently, the wear indicator is exposed as a sign to the user that the cleat should be replaced. The color of the wear indicator may contrast with the color of traction elements to provide a visible sign to the user that the ground-engaging surface of the cleat has worn away.

The ground-facing face 26 of the cleat disc 24 supports the cushioning layer 30 of the cleat 10. The cushioning layer provides resilience or "bounce" to the cleat. The cushioning layer may be made of plastic or rubber or another compressible material. In specific embodiments of the invention, the cushioning layer material preferably ranges in durometer from Shore 1OA to Shore 7OA. In some embodiments, the cushioning layer may take on a regular, convex shape. (See fig. 5, cushioning layer 40, for example, where the cushioning layer is formed as a disc). In other embodiments, the cushioning layer may include one or more cutouts or notches. (See, for example, fig. 1 where cushioning layer 30 includes six regularly spaced cutouts 42. The number of cutouts may also be any number smaller than six or greater than six.) The cushioning material can expand into the space formed by these cutouts 42 as the traction elements above the cushioning layer make ground contact, compressing the cushioning layer. The resilience or bounce provided by the cushioning layer to the shoe attachment element and the traction elements is thereby enhanced.

The traction element assembly 40 of the cleat engages the ground surface, providing traction for the user. The traction element assembly of the cleat may be formed with traction elements in a variety of shapes and sizes and with various materials. The traction element assembly 40 provides protection for the relatively softer cushioning layer 30, as the cleat contacts the ground surface. Note that the term "traction element assembly" does not imply that all of the traction elements are necessarily connected in each embodiment of the invention. Some, all or none of the elements may be connected together in a traction element assembly.

In the embodiment of the invention shown in figs. 1 and 2, the traction element assembly consists of six traction teeth 54 connected to a central hub 51 by individual spokes 52. This traction element assembly structure allows each traction tooth (and spoke) to flex independently of each other tooth and spoke when contacting the ground surface. The cushioning layer supports and cushions each traction tooth independently of each other traction tooth. The cushioning layer provides the restoring force to return the traction tooth and spoke to its original position, as a cleat traction tooth leaves the ground surface as the wearer walks. The cushioning layer will flex into the space between the spokes as the spokes move. The traction teeth at the ends of the spokes (which spokes are also known as flex beams) are the primary traction points for the cleat. In various specific embodiments of the invention, these teeth can be of any shape (conical, square, pyramidal, frusto-conical, etc), of any length or height, and may have any shape tip (pointed, blunt, domed, slanted inward, slanted outward, etc). The number of teeth at the end of a spoke is variable and the number of spokes connected to a disc may number more or less than six. The axis of each tooth is preferably oriented at a maximum of 90 degrees to the plane of the cleat (i.e., to the plane of the outsole when installed), or may be substantially less than 90 degrees (e.g., angled toward the center of the disc). The hub at the center of the traction element assembly may be solid or the hub may have an opening to accommodate a wear indicator or to allow material in the cushioning layer to flex through the opening. In a preferred embodiment of the invention, a plurality of such cleats is provided on a shoe outsole. The independent flexing of the traction elements within a cleat and across the plurality of cleats supplies traction that adapts well to uneven surfaces. In embodiments of the invention, the durometer of the traction elements ranges preferably from about Shore 6OA to about Shore 98 A. In specific embodiments of the invention, the traction elements are formed from a thermoplastic material, such as polyurethane. In some embodiments of the invention, the traction elements are each similar in construction and arranged in a symmetrical pattern around the perimeter of the cushioning layer. In other embodiments, the traction elements may differ in size, shape, and/or material and may be placed asymmetrically with respect to the perimeter of the cushioning layer. In each embodiment, the cushioning material provides resilient backing for the harder traction element assembly positioned on it when the user puts weight on the cleat through the shoe outsole. The disc, being formed of a material that is less resilient than the cushioning layer, provides support for the cushioning layer. The traction element assembly may be formed to fully cover the cushioning layer, providing a high level of protection for the cushioning layer from surface contact, or may cover only a portion of the cushioning layer. As described above, the cushioning layer may include notches that allow the cushioning material to expand into the notches as the traction elements apply pressure to the cushioning layer. These notches can also allow the traction elements to twist from side-to-side as the cushioning material flexes to fill the notches. This traction element twisting action can provide for enhanced traction on uneven surfaces.

In preferred embodiments of the invention, the cushioning layer material and the traction element assembly material are matched so that the difference in durometer between the cushioning layer and the traction element assembly ranges from about 10 to about 70 points on the Shore durometer scale. In various embodiments of the invention, the materials may be tailored for factors such as the characteristics of the shoe wearer or the characteristics of the ground surface. For example, a heavier player may be provided with a cleat with a cushioning layer material that is (relatively) harder, coupled with a correspondingly harder traction element material. A smaller or lighter weight player may be provided a cleat with corresponding softer elements. As a second example, for play on dry, hard, firm ground a cleat with a larger spread between the hardness of the cushioning layer and the traction element assembly may be provided. For play on wet or soft ground, a cleat with a smaller spread between the hardness of the elements may be advantageously employed.

Figs. 3-5 show another illustrative embodiment of the invention. This embodiment is similar to the embodiment shown in figs. 1-2, except that the cushioning layer is formed as a disc without notches. (A common numbering scheme is used for the features in figs. 3-5 and in figs. 1-2). In another embodiment of the invention, as shown in figs. 6A and 6B, a cleat includes traction elements (110, 115) connected directly to the second face (ground-engaging face) 120 of a shoe attachment portion disc 120. Fig. 6A is a perspective view of the ground-engaging face of the cleat. The cushioning material 125 is inserted into slots formed in a face of traction elements 110. This face of the traction element faces the center of the ground-facing face 120 of the disc. Fig. 6B shows a traction element 110 in cross section with the cushioning material 125 on the traction element face. The elastic nature of the cushioning material provides a restoring force as a traction tooth compresses the cushioning material under the weight of a user. Likewise, if the traction element 110 is twisted away from the center of the cleat disc, the elasticity of the cushioning material will provide a restoring force, tending to return the traction element to its upright position. In a further related embodiment, as shown in figs. 6C and 6D, a cleat 200 includes traction elements (210, 215) connected directly to the second face (ground- facing face) of a shoe attachment portion disc (not shown). Traction elements 210 include cushioning material 225 inserted into slots formed in the face of traction elements 210, as shown in fig. 6D. This face of the traction element faces away from the center of the ground- facing face of the cleat disc. The elastic nature of the cushioning material provides a restoring force as the traction teeth compress the cushioning material under the weight of a user. Likewise, if the traction element 210 is twisted inward toward the center of the cleat, the elasticity of the cushioning material will provide a restoring force, tending to return the traction element to its original orientation.

In other embodiments of the invention, a traction element may be provided with the cushioning material embedded into any face of the traction element. Further, a traction element may have cushioning material embedded into more than one face of the element. For example, a traction element may have cushioning material embedded into two faces of the element with one face oriented towards the center of the cleat disc and another face oriented away from the center of the disc. The traction elements for a cleat may be all of a common type or may include any mix and placement of traction elements with different patterns of cushioning material in traction element faces.

Debris Skirt

In other embodiments of the invention, a removable footwear cleat includes a cushioning layer with a debris skirt. The debris skirt prevents dirt, grass and other material from entering and clogging the space between the cleat and outsole of a shoe. The cleat comprises a shoe attachment portion; a cushioning layer directly engaging the shoe attachment portion; and a traction element assembly, positioned on the cushioning layer. The shoe attachment portion includes a disc with opposing faces. One face of the disc includes a shoe attachment element that removably attaches the cleat to a corresponding element (e.g., receptacle) in a shoe outsole. The opposing face of the disc supports the cushioning layer. The perimeter of the cushioning layer includes a debris skirt. When installed on the shoe, the skirt extends toward the outsole of the shoe. When the cleat is fully engaged with the receptacle, the skirt contacts the outsole, forming a barrier to debris. The structure of the cushioning layer between the skirt and the second face of the disc can allow the debris skirt to deflect when pressure from ground contact forces the traction element into the cushioning layer. Such debris skirt deflection increases the resiliency of the cushioning layer at the layer's perimeter, enhancing user comfort and protection of the turf surface.

An example of a cleat 700 with a debris skirt is shown in fig. 7, according to an embodiment of the invention. Fig. 7A shows a perspective view of the ground engaging face of the cleat 700. A plurality of traction elements 704 are connected via spokes to a center hub 751, forming a traction element assembly. The traction element assembly engages a cushioning layer 706. The cushioning layer includes a skirt 708 which extends upwards and typically contacts the shoe outsole, when the cleat is installed in the shoe. A cleat wrench can engage pin shafts 710 in the ground engaging face of the cleat to install the cleat into the shoe. Fig. 7B shows a perspective view of the shoe attachment portion of the cleat 700. The shoe attachment portion includes a disc 714 with opposing faces, one face of which is visible in fig. 7B, and a male shoe attachment element 712. The shoe attachment element 712 is inserted into a receptacle in the shoe outsole and rotated to attach the cleat to the shoe. The shoe attachment face of the disc 714 includes a perimeter 718, which, in this embodiment, is generally circular. The cushioning layer 706 includes a hollow portion 716 between the disc perimeter 718 and debris skirt 708. Fig. 8 shows a cutaway perspective view of the structure of the cleat 700 from the ground engaging side of the cleat. As shown in fig. 9, when pressure is applied to a traction element 704 by contact with the ground surface, the debris skirt bends upward toward the shoe. The hollow 716 behind the debris skirt allows the portion of the skirt which contacts the outsole to slide outwardly from the disc's center. The debris skirt at once prevents debris from migrating towards the shoe attachment element of the cleat and provides additional cushioning to the traction element as the bottom of the skirt slides outwardly. In other embodiments, similar debris skirts may be provided on cleats without cushioning.

In a related specific embodiment of the invention, the outer perimeter 1006 of the cushioning layer of a cleat 1000 forming the debris skirt may include folds, like an accordion or bellows, as shown in fig. 10. As illustrated in fig. 11, the folds allow the outer face of the cushioning layer to resiliency deflect upwards towards the shoe when pressure is applied to a traction element 1004. The folds permit the face of the cushioning layer to bend upward towards the outsole without deflecting substantially outward from the center of the disc.

In another specific embodiment of the invention, as shown in fig. 12, the cushioning layer of the cleat 1200 may include cutouts such that the cushioning layer is not rotationally symmetrical about the axis of the shoe attachment element (not shown) of the disc 1214. As described previously, this arrangement allows the cushioning material to expand into the cutouts as pressure is applied to the traction elements 1204 and spokes 1252 of the traction element assembly, enhancing the cushioning effect. A cavity 1216 is provided behind the outer perimeter 1208 of the cushioning layer 1206. This cavity can trap air which provides an additional cushioning effect as pressure is applied to the traction element above the cavity. The air trapped in the cavity 1216 by the outsole of the shoe can escape relatively slowly providing an additional measure of resiliency for the traction element assembly. While three cutouts (and spokes) are shown for this embodiment, any number of spokes and cutouts can be employed in various embodiments of the invention.

Mechanical Attachment of Traction Elements to Cleat

In other embodiments of the invention, traction elements or a traction element assembly are attached mechanically to the shoe attachment portion of a cleat. The shoe attachment portion of the cleat comprises a disc with opposing faces attached to a shoe attachment element. One face of the disc supports a cushioning layer between the traction element assembly and the disc. Mechanical attachment of the traction elements to the shoe attachment portion of the cleat allows a wider range of materials to be used for cleat components than are possible with a bonded coupling.

The traction element assembly may be coupled to the shoe attachment portion in one of several ways. First, the traction element assembly may be fabricated as a structure separate from the shoe attachment portion. The assembly may then couple mechanically to the shoe attachment portion with a fastener. The assembly may include an integral fastener which attaches to the cleat or a separate fastener, such as a rivet, may couple the traction element assembly to the cleat. Second, traction elements forming the assembly may be fabricated as part of the shoe attachment portion disc, typically on the disc's perimeter. These elements can then fold over towards the center of the disc. For example, the traction elements can attach to the face of the disc with a fastener, such as a rivet, or a portion of the traction element can serve as a coupling element (male or female) mating to the complementary element on the face of the disc.

An illustrative embodiment of this aspect of the invention is shown in figs. 13 to 15. Fig. 13 is an exploded view of a cleat 1300. The traction element assembly 1310 couples a cushioning layer 1320 to the shoe attachment portion 1330 of the cleat. The traction element assembly 1310 includes an integral snap-fit coupler 1315. To assemble the cleat, the cushioning layer 1320 is placed on the shoe attachment portion 1330 or bonded to it. The snap-fit coupler of the traction element assembly 1310 may then be inserted through the hole in the cushioning layer and into the hole in the center of the shoe attachment portion of the cleat. Thus, a sandwich of the three structures is formed. In other embodiments of the invention, a variety of coupler element types may be used, as are known in the art. Fig. 14 shows a perspective view of the assembled cleat 1300 and fig. 15 shows a cross-sectional view of the cleat. In a specific embodiment of the invention, the integral coupler can be replaced with a separate rivet that fits through the traction element assembly and attaches the traction element assembly 1310 to the disc 1330.

In another illustrative embodiment of the invention, as shown in fig. 16, a separate fastener (in this case, a rivet) connects one end of each traction element to the shoe attachment portion of a cleat 1600. The cleat includes a disc 1610 with opposing faces, a traction element array 1620, one or more fold-over traction elements 1630, and a rivet 1640. The traction element array 1620 engages the ground-facing face of the disc 1610. The array 1620 may be bonded to this face of the disc. As shown in fig. 17, each traction element 1630 is attached on one end to the perimeter of the disc 1610, with the other end of the traction element free to move. Each traction element 1630 can be folded over towards the center of the disc 1610. A rivet 1640 can then be inserted into the center of the disc 1610. This rivet attaches the free end of each traction element 1630 to the face of the disc. Figure 17 illustrates the operation of folding over the traction element 1630 and attaching the element to the face of the disc 1610 with a rivet 1640. The flex of the traction elements 1630 when it is folded over to the center of the disc advantageously enhances the wearer's comfort as the cleat impacts the ground surface. In some embodiments of the invention, cushioning material may be bonded to the disc face over which the traction elements fold, providing additional resiliency to the flex of the folded-over traction element.

In another embodiment of this aspect of the invention, as shown in fig. 18, each traction element 1800 includes a coupling element 1810 on the traction element's free end. The traction element 1800 is folded over and the coupling element 1810 is inserted into a corresponding coupling element 1840 in the ground-facing face of the disc 1830. The traction element 1800 forms a cavity 1850 when the element is folded over and coupled to the ground-facing face of the disc. Cushioning material may be placed on the face of the disc so that this material fits into the cavity 1850 formed by the folded-over traction element 1800. When pressure from the outsole of the shoe forces the traction surface 1820 of the traction element 1800 into the turf as the wearer steps, the flex of the traction element and the resiliency of the cushioning layer advantageously enhance the wearer's comfort. While a male coupling element 1810 is shown at the end of the traction element 1800, in specific embodiments of the invention, the traction element may include a female coupling element at its free end with a corresponding male coupling element embedded in the disc.

In specific embodiments of the invention, any of the above cleat embodiments may include one or more of the following variations:

The shoe attachment element structure may employ any structure known in the art, such as a threaded stud, a Q-LOK™ structure, a TRI-LOK™ structure, etc.

The durometer of the traction elements may range from about Shore 6OA to about Shore 98A.

The cushioning layer material may range in durometer from about Shore 1OA to about Shore 80A and may comprise plastic or rubber or another compressible material. The cushioning layer material and the traction element or traction element assembly material can be matched so that the difference in durometer between the cushioning layer and the traction element assembly ranges from about 10 to about 70 points on the Shore durometer scale.

The cleat materials may be tailored for factors such as the characteristics of the shoe wearer or the characteristics of the ground surface, such as natural turf or synthetic surfaces.

For example, a heavier player may be provided with a cleat with a cushioning layer material that is (relatively) harder, coupled with a correspondingly harder traction element material. A smaller or lighter weight player may be provided a cleat with corresponding softer elements. As a second example, for play on dry, hard, firm ground a cleat with a larger spread between the hardness of the cushioning layer and the traction element assembly may be provided. For play on wet or soft ground, a cleat with a smaller spread between the hardness of the elements may be advantageously employed.

Cleat Fabrication

The cleats described above may be fabricated using conventional techniques, as are known in the art, such as injection molding. In one preferred method of fabricating a cleat, a two-step process is employed. First, one element, either the traction element or the shoe attachment portion of the cleat, is molded. Then, this first element is used as an "insert" in a two-color and two-injection plastic molding machine. This second operation molds two elements, in two different colors, and bonds the three elements together. Note that each or any of the three elements can be of similar or different materials and durometers. In practice, the single "insert element" may be loaded into the second machine either by hand, or automatically by a "pick and place" robotic arm. In a second preferred method, the traction element and the attachment element are made separately in injection plastic molding machines, as individual pieces. Then, these separate pieces are loaded as inserts into a second machine. In the second machine, the third material is injected into the middle, bonding the cleat together.

Cushion Cleat Embedded in a Shoe

In further embodiments of the present invention, any of the footwear cleat embodiments described above may be attached to the sole of a shoe in a non-removable fashion. For example, a footwear cleat may comprise a base layer with a shoe attachment element, a cushioning layer directly engaging the base and a traction element layer, contacting the cushioning layer. Thus, this non-removable cleat forms a "sandwich." The cleat base includes a top portion and a bottom portion with a shoe attachment flange extending generally laterally from the top portion of the base. ("Top" and "bottom" refer to the orientation when the shoe engages the ground.) This flange retains the cleat in the shoe outsole, when the ground engaging portion of the cleat is inserted through a hole in the top of the outsole. The outsole is then over-molded, locking the cleats into the outsole. When a user steps on a surface wearing a shoe outfitted with these cleats, the resilience (i.e., "give") of the cushioning layer at once both lessens the impact of the traction elements on the ground surface and lessens the reaction force on the user's foot, as transmitted through the shoe's outsole. The user's comfort is thereby enhanced.

Figs. 19-22 illustrate one embodiment of a cushion cleat embedded in a sports shoe outsole. Fig. 19 shows a cushion cleat 1910 in cross section. The cleat 1910 comprises a traction element layer 1930, a cushioning layer 1925 and a base layer 1920. The base layer is formed with a flange 1915 to retain the cleat after insertion into a corresponding hole in a shoe outsole. The cleat 1935 in the finished shoe is adapted to engage and provide friction with the ground. Fig. 20 shows cleats 1910 positioned for insertion into a series of holes 2040 in a shoe outsole 2005. Fig. 21 shows the outsole 2005 with cushion cleats 1910 after the outsole is over-molded to embed the cleats 1910 into the outsole 2005. A cut away view of one cleat 2110 is provided in fig. 21 to show the position of the cleat relative to the outsole. Fig. 21 shows that each of the base layer, the cushioning layer and the traction element layer in this embodiment is adapted to provide friction with the ground when the cleat engages the ground. The flange 1915 retains the cleat insert in the outsole, after over- molding. In other specific embodiments of the invention, the shoe outsole attachment element of the base can assume shapes other than a flange - any shape that will retain the insert in the outsole after over-molding can be employed. The shape of the flange perpendicular to the axis of the cleat can be circular, rectangular, an ellipse, irregularly shaped, etc. Fig. 22 is a perspective view of the ground engaging side of a finished shoe 2200, showing an illustrative layout of cushion cleats 1910 embedded in the outsole. The number and placement of cleats in an outsole can vary in various embodiments of the invention, depending on the requirements for traction and user comfort for the particular sport for which the shoe is intended. Fig. 23 shows another illustrative layout of cushion cleats in a finished shoe 2300. Some cushion cleats and the corresponding holes in the outsole will not be symmetrical about the cleat's (and hole's) axis. These embodiments of the invention can advantageously provide directional traction for the sport shoe.

The ground engaging portion 1935 of the cushion cleat insert 1910 can be of any shape (e.g., conical, rectangular, pyramidal, frusto-conical, etc.); of any length, width, diameter or height; and, may have any shape tip (e.g., pointed, blunt, domed, slanted inward, slanted outward, etc). For example, the cleats 2310 in the shoe 2300 shown in fig. 23 differ in shape from the cleats in fig. 19 and vary in width and orientation with respect to the front and rear of the shoe. The thickness of the layers (1920, 1925, 1930) may vary among the various layers. While the components of embedded cushion cleats have been described as "layers," more complex shapes as previously described in connection with removable cushion cleats may be employed in these embedded cushion cleats.

As shown in fig. 19, in embodiments of the invention, the cushioning layer 1925 extends laterally from side to side of the ground engaging portion of the cleat 1935, so that the traction element layer 1930 does not directly engage with base 1920. Thus, the cushioning layer alone, for this embodiment, secures the traction element layer to the base layer. The inventors were surprised to find that when the durometer of the cushioning layer ranges from about Shore 65 A to 75 A, attachment of the traction element layer to the base layer by the cushioning layer provides sufficient tear strength to withstand sheer stresses typical of a variety of action sports, such as soccer, lacrosse, cross-country track, etc. This range of durometers for the cushioning layer, for this preferred embodiment, was determined after considerable experimentation to provide a suitable trade-off of strength of adhesion of the traction element layer to the base layer versus the amount of cushioning desirable for user comfort. Increasing the durometer of the cushioning layer improves the adhesion of the traction element layer to the base layer, but decreases the cushioning effect. The durometer of the traction element layer is selected to be above the durometer of the cushioning layer for the cleat, preferably from about Shore 80A to about Shore 98 A; and the durometer of the base layer is preferably about Shore 64D or greater. In other embodiments of the invention, the durometer of the cushioning layer may be in the range from about Shore 75 A to about Shore 80 A with the durometer of the traction element layer above Shore 80A. In alternative preferred embodiments of the invention, the traction element layer

1930 extends through portions of the cushioning layer 1925 to engage directly with the base. The durometer of each of the layers can vary according to the needs of the sport and the user of the sport shoe (e.g., child, adult, amateur, professional, etc.). In specific embodiments of the invention, the durometer of the cushioning layer material preferably ranges from Shore 65 A to Shore 75 A; the durometer of the traction element layer ranges above the durometer of the cushioning layer for the cleat, preferably from about Shore 8OA to about Shore 98 A; and the durometer of the base layer is preferably about Shore 64D or greater. Note that each of the layers may include more than a single material. For example, a layer may comprise a sandwich of materials to achieve a preferred mixture of resilience and durability.

In various embodiments of the invention, every cushion cleat 1910 in a shoe outsole need not be alike. The construction of the cushion cleats may vary across the shoe outsole to meet particular traction and user comfort requirements. For example, the cleats in a particular shoe may vary among themselves in any of the fashions described in the preceding discussion. In various embodiments of the invention, the colors of the several layers of the cleat insert can vary or can all be the same. For example, the cushioning layer and the traction element layer can differ in color so that wear of the traction element layer, such that the cushioning layer may be compromised, becomes apparent.

Embedded Cushion Cleat Fabrication

The non-removable cushion cleats described above may be fabricated using conventional techniques, as are known in the art, such as injection molding, die cut and assembly (adhered, glued, etc.), compression and flow molding, casting, etc.. This process may be similar to the process described above for removable cleats. In one preferred method of fabricating a cleat, a two-step process is employed. First, one element, either the traction element layer or the base layer, is molded. Then, this first element is used as an "insert" in a two-color and two-injection plastic molding machine. This second operation molds the other two elements, in different colors if desired, and bonds the three elements together using pressure. In practice, the single "cleat insert element" may be loaded into the second machine either by hand, or automatically by a "pick and place" robotic arm. The inventors found that when the durometer of the cushioning layer material was selected with a suitable hardness, such as Shore 65 A to 75 A, the injected cushioning layer material could serve in effect as a mold for the subsequent injection of the material for the traction element layer. A durometer in the range of Shore 65 A to 75 A for the cushioning layer is important so that the pressure used for bonding the traction element layer to the cushioning layer does not overly compress the cushioning layer, distorting the cleat. This range of durometer of Shore 65 A to 75 A for the cushioning layer material thus proved advantageous to provide a cleat that could be successfully fabricated, would hold together when used in athletic competitions and would also provide a desirable cushioning effect for users. Holes or cutouts may be provided in any face of any of layer of the above described cleats to facilitate bonding of one layer to the next during the injection molding process. Once formed by this process, the completed cleats are then inserted into the outsole from the top side and then over-molded to retain the cushion cleat in the outsole.

The cushion cleats may also be formed and molded into the shoe using a unitary injection molding process. In this process, cushion cleat inserts are not formed as separate parts, and then mated with the outsole. Instead, the outsole with cushion cleats is formed in a single mold. Fig. 24 shows a side, cut-away view of a shoe outsole 2405 with embedded cushion cleats 2410 formed in the outsole of a shoe using injection molding, according to an embodiment of the invention. Multiple, e.g., four, materials are injected into the mold in turn: one material forms the outsole and three materials form the layers of the cushion cleat. The cushion cleat's 2410 composition, shape and color can be selected from any of the alternatives described above in connection with the non-removable cushion cleat insert 1910. Fig. 25 shows a further embodiment of the invention. In this embodiment, the outsole 2505 and the base layer of the cushion cleat 2510 are formed from the same material in a single injection molding step. Note that the material used for forming each layer of the cushion cleat is not limited to a single material for each layer. More than one material may be injected for any layer in the embedded cushion cleat. In preferred embodiments of the invention, the use of a durometer in the range of Shore 65 A to 75 A for the cushioning layer and the use of the cushioning layer as a "mold" for the traction element layer, as described above, may be advantageously applied to this form of the embedded cushion cleat as well. In a further embodiment of the invention, as shown in fig. 26, a cushion cleat plate 2620 is embedded in a shoe outsole. Fig. 26A illustrates the ground engaging side of the finished shoe, schematically. Embedded cushion cleat plates 2620 with cleat projections 2630 are provided for heel and toe portions of the shoe. Embedded cushion cleats 2610, as described above, are provided for the midsole area. Note that the dimensions and number of traction plates and number of cleat projections in each area of the shoe are shown in fig. 26 for illustration only, and not by way of limitation. In specific embodiments of the invention, the number and placement of plates, cleat projections and cushion cleats embedded in the outsole can vary.

Fig. 26B shows a cutaway view of the outsole of fig. 26A, along line "A". In this embodiment, the durometer of the tip of the cleat projections 2630 is highest, the outsole material 2605 is lowest in durometer, and the durometer of the cushion cleat plates 2620 is intermediate between the cleat projection tip and the outsole. Note that the resilient outsole material 2605 provides cushioning between the cleat projection tip 2630 and the cleat plate 2620. In the embodiment shown in fig. 26C, the cleat projection tip 2630 bonds directly to the traction plate.

Embedded cushion cleat plates 2620 with cleat projections 2630, as illustrated in fig. 26, may be fabricated as described above for embedded cushion cleats. The outsole 2605, embedded cushion cleat plates 2620 and cleat projections 2630 may all be molded in the same unitary process. Alternatively, the cleat projections tips 2630 and outsole/cleat plate combination may be molded separately and loaded into another machine for bonding together. In another embodiment of the invention, a removable version of the "embedded" cushion cleat shown in figs. 19-22, and described above, is provided. The base layer of this embodiment of the cushion cleat is formed with a shoe attachment element adapted for removable attachment to the shoe in place of the flange 1915. This shoe attachment element removably secures the cleat in a shoe outsole after insertion of the element into a corresponding receptacle that is molded into the outsole. The shoe attachment element and the corresponding receptacle may be constructed according to the Q-LOK™ system (as described in U.S. patent nos. 5,768,809, 6,151,805, 6,108,944, and 6,463,681), to the Fast Twist™ system (as described in U.S. patent nos. 5,123,184, 5,524,367, 5,974,700 and 6,272,774), to a threaded structure and corresponding threaded receptacle, to snaps and locks, or to any other structure that can removably attach a ground-engaging cleat to a receptacle. This removable cushion cleat includes a base layer, a cushioning layer and a traction element layer that each provide frictional engagement with the ground when the cleat engages the ground. Like the cleat shown in fig. 19, the cleat of this embodiment provides a cushioning layer 1925 that extends laterally from side to side of the ground engaging portion of the cleat 1935, so that the traction element layer 1930 does not directly engage with the base layer 1920. Thus, the cushioning layer alone, for this embodiment, secures the traction element layer to the base layer. The durometer of the cushioning layer is less than the durometer of the base layer and the durometer of the traction element layer. Preferred embodiments of this removable cleat include a cushioning layer with a durometer in the range from Shore 65 A to 75 A. These removable cleats may be fabricated by injection molding as described above.

Similarly, it is of course apparent that the present invention is not limited to the detailed description set forth above. Various changes and modifications of this invention as described will be apparent to those skilled in the art without departing from the spirit and scope of this invention as defined in the appended claims.