Cleats, cleated sole structures, molds, and molding methods for in-molding articles

Abstract

Cleat structures, e.g., for golf shoes, may include a flat and flexible interior surface and/or a generally disk-shaped perimeter area that includes features to promote in-molding of the cleat to a footwear sole component (e.g., to permanently engage the cleat with an outsole member). Such cleats may provide a flexible and comfortable base, including a low profile, e.g., to enable formation relatively thin and/or flexible footwear sole components. Footwear sole components and articles of footwear that include one or more in-molded cleat structures of this type also are described. Molds used for in-molding procedures and methods of using the molds to make articles with in-molded components (e.g., for making footwear sole structures including one or more in-molded cleats) also are described.

What is claimed is: 
     
         1 . A sole element for an article of footwear, comprising:
 a cleat including an interior surface, an exterior surface opposite the interior surface, and an outer flange, wherein the outer flange includes a first surface, a second surface opposite the first surface, and an outer perimeter edge extending between the first and second surfaces, wherein a plurality of perimeter openings extending through the outer flange are located adjacent the outer perimeter edge; and   a sole component engaged with the cleat, wherein the sole component includes a continuous layer of material that covers the outer perimeter edge, extends over the first and second surfaces of the outer flange, and through the plurality of perimeter openings.   
     
     
         2 . A sole element according to  claim 1 , wherein at least 95% of a bottom surface of the sole component is planar, substantially planar, or smoothly curved. 
     
     
         3 . A sole element according to  claim 1 , wherein the sole component completely covers the interior surface of the cleat. 
     
     
         4 . A sole element according to  claim 1 , wherein the sole component constitutes an outsole component. 
     
     
         5 . A sole element according to  claim 1 , wherein the sole component includes an exterior base area and a plurality of traction elements integrally formed with the sole component and extending outward from the exterior base area. 
     
     
         6 . A sole element according to  claim 5 , wherein the exterior base area of the sole component exclusive of a thickness of the traction elements has a maximum thickness of 7 mm or less. 
     
     
         7 . A sole element according to  claim 5 , wherein the sole element has a maximum thickness through the cleat and the sole component of 15 mm or less. 
     
     
         8 . A sole element according to  claim 1 , wherein the continuous layer of material completely covers the plurality of perimeter openings. 
     
     
         9 . A sole element according to  claim 1 , wherein at least 95% of the interior surface of the cleat is planar, substantially planar, or smoothly curved. 
     
     
         10 . A sole element according to  claim 1 , further comprising:
 a second cleat including a second interior surface, a second exterior surface opposite the second interior surface, and a second outer flange, wherein the second outer flange includes a third surface, a fourth surface opposite the third surface, and a second outer perimeter edge extending between the third and fourth surfaces, wherein a second plurality of perimeter openings extending through the second outer flange are located adjacent the second outer perimeter edge, and wherein the continuous layer of material of the sole component additionally covers the second outer perimeter edge, extends over the third and fourth surfaces of the second outer flange, and extends through the second plurality of perimeter openings.   
     
     
         11 . A sole element according to  claim 10 , wherein at least 95% of a bottom surface of the sole component is planar, substantially planar, or smoothly curved. 
     
     
         12 . A sole element according to  claim 10 , wherein the sole component completely covers the interior surface of the cleat. 
     
     
         13 . A sole element according to  claim 10 , wherein the sole component constitutes an outsole component. 
     
     
         14 . A sole element according to  claim 10 , wherein the sole component includes an exterior base area and a plurality of traction elements integrally formed with the sole component and extending outward from the exterior base area. 
     
     
         15 . A sole element according to  claim 14 , wherein the exterior base area of the sole component exclusive of a thickness of the traction elements has a maximum thickness of 7 mm or less. 
     
     
         16 . A sole element according to  claim 10 , wherein the continuous layer of material completely covers the plurality of perimeter openings and the second plurality of perimeter openings. 
     
     
         17 . A sole element according to  claim 10 , wherein at least 95% of the interior surface of the cleat is planar, substantially planar, or smoothly curved, and wherein at least 95% of the second interior surface of the second cleat is planar, substantially planar, or smoothly curved. 
     
     
         18 . A sole element according to  claim 1 , further comprising:
 a second cleat including a second interior surface, a second exterior surface opposite the second interior surface, and a second outer flange, wherein the second outer flange includes a third surface, a fourth surface opposite the third surface, and a second outer perimeter edge extending between the third and fourth surfaces, wherein a second plurality of perimeter openings extending through the second outer flange are located adjacent the second outer perimeter edge; and   a third cleat including a third interior surface, a third exterior surface opposite the third interior surface, and a third outer flange, wherein the third outer flange includes a fifth surface, a sixth surface opposite the fifth surface, and a third outer perimeter edge extending between the fifth and sixth surfaces, wherein a third plurality of perimeter openings extending through the third outer flange are located adjacent the third outer perimeter edge, and wherein the continuous layer of material of the sole component additionally covers the second and third outer perimeter edges, extends over the third, fourth, fifth, and sixth surfaces, and extends through the second and third plurality of perimeter openings.   
     
     
         19 . An article of footwear, comprising:
 an upper; and   a sole structure engaged with the upper, wherein the sole structure includes a sole element having:   a cleat including an interior surface, an exterior surface opposite the interior surface, and an outer flange, wherein the outer flange includes a first surface, a second surface opposite the first surface, and an outer perimeter edge extending between the first and second surfaces, wherein a plurality of perimeter openings extending through the outer flange are located adjacent the outer perimeter edge; and   a sole component engaged with the cleat, wherein the sole component includes a continuous layer of material that covers the outer perimeter edge, extends over the first and second surfaces of the outer flange, and through the plurality of perimeter openings.   
     
     
         20 . An article of footwear according to  claim 19 , wherein the article of footwear is a golf shoe. 
     
     
         21 . An article of footwear according to  claim 19 , wherein the sole structure includes a midsole component engaged with the upper, and wherein the sole element is engaged with the midsole component. 
     
     
         22 . An article of footwear according to  claim 19 , wherein the sole structure further includes a second sole element having:
 a second cleat including a second interior surface, a second exterior surface opposite the second interior surface, and a second outer flange, wherein the second outer flange includes: (a) a third surface, (b) a fourth surface opposite the third surface, and (c) a second outer perimeter edge extending between the third and fourth surfaces, wherein a second plurality of perimeter openings extending through the second outer flange are located adjacent the second outer perimeter edge; and   a second sole component engaged with the second cleat, wherein the second sole component includes a continuous layer of material that covers the second   outer perimeter edge, extends over the third and fourth surfaces of the second outer flange, and through the second plurality of perimeter openings.   
     
     
         23 . An article of footwear according to  claim 22 , wherein the article of footwear is a golf shoe. 
     
     
         24 . An article of footwear according to  claim 22 , wherein the sole structure includes a midsole component engaged with the upper, and wherein the first sole element is engaged with the midsole component and the second sole element is engaged with the midsole component. 
     
     
         25 . An article of footwear according to  claim 24 , wherein the first sole element is located in a forefoot area of the midsole component and the second sole element is located in a heel area of the midsole component.