Traction elements for athletic shoes and methods of manufacture thereof

Abstract

Various embodiments for a traction element used with athletic shoes having a stud body with a metal insert that extends axially from the stud body and methods for manufacturing such traction elements are disclosed.

What is claimed is: 
     
         1 . A method of manufacturing a traction element comprising:
 casting a stud body with a metal insert, the stud body having a distal head portion and a proximal end portion, wherein the metal insert defines a shaft portion formed between a distal cap portion and a proximal threaded portion, wherein the metal insert is cast with the stud body such that the proximal threaded portion of the metal insert extends axially outwardly at a predetermined distance from the stud body; and   coring out the proximal end portion of the stud body to form an interior cavity.   
     
     
         2 . The method of  claim 1 , further comprising:
 forming a plurality of cutaways along an outer surface of the stud body.   
     
     
         3 . The method of  claim 1 , further comprising:
 filling the interior cavity with a filler material to form a retainer that provides structural integrity to the metal insert relative to the stud body.   
     
     
         4 . The method of  claim 3 , wherein the filler material comprises a nylon material. 
     
     
         5 . The method of  claim 3 , wherein the metal insert comprises a bulbous portion formed between the shaft portion and the proximal threaded portion of the metal insert and being configured to engage the retainer for retaining the metal insert to the stud body. 
     
     
         6 . A method of manufacturing a traction element comprising:
 casting a stud body, the stud body having a distal head portion and a proximal end portion;   coring out the proximal end portion of the stud body to form an interior cavity;   driving a metal insert into the interior cavity such that the metal insert cuts into an interior surface of the interior cavity to securely engage the metal insert with the stud body.   
     
     
         7 . The method of  claim 6 , wherein the metal insert comprises a distal head portion, a proximal threaded portion and a plurality of drive grippers extending radially outward from the proximal threaded portion adjacent the distal head portion. 
     
     
         8 . The method of  claim 7 , wherein driving the metal insert into the interior cavity comprises engaging the plurality of drive grippers with a driving tool and rotating the metal insert into the interior cavity. 
     
     
         9 . The method of  claim 7 , wherein the plurality of drive grippers comprises a plurality of radially extending arms. 
     
     
         10 . The method of  claim 7 , wherein the distal head portion forms a standard or reverse thread head configured for cutting into a surface of the stud body when engaging the metal insert with the stud body. 
     
     
         11 . A traction element comprising;
 a cored out stud body defining an interior cavity, a distal head portion, and a proximal end portion, the stud body configured to be attached to a sole of a shoe; and   the interior cavity of the cored out stud body comprising a light weight filler material; and   a metal insert coupled to the stud body, the metal insert extending axially from the stud body.   
     
     
         12 . The traction element of  claim 11 , wherein the stud body is thimble shaped, the thimble shaped configured to provide traction and gripping strength along a ground surface. 
     
     
         13 . The traction element of  claim 11 , wherein the metal insert is configured to mechanically couple the traction element to the sole of the shoe. 
     
     
         14 . The traction element of  claim 11 , wherein the proximal end portion of the stud body tapers away from the distal head portion and forms a peripheral flange that defines an opening in communication with an interior cavity formed within the stud body. 
     
     
         15 . The traction element of  claim 11 , wherein the metal insert comprises at least a steel or aluminum material. 
     
     
         16 . The traction element of  claim 11 , wherein the metal insert further defines a bulbous portion formed between a shaft portion and a proximal threaded portion, the bulbous portion configured to provide an engagement surface for a retainer or liner disposed inside an internal cavity. 
     
     
         17 . The traction element of  claim 11 , wherein a plurality of cutaways may be formed axially along an outer surface of the stud body, the plurality of cutaways collectively configured to receive a driving tool. 
     
     
         18 . The traction element of  claim 11 , wherein each of the plurality of cutaways define an elongated slot configuration forming a base proximate to a peripheral flange of the stud body. 
     
     
         19 . The traction element of  claim 11 , wherein the plurality of cutaways define at least one of a triangularly-shaped slot, a rectangular shaped slot, a symmetrically shaped slot, an asymmetrically shaped slot, and a circular shaped slot. 
     
     
         20 . The traction element of  claim 11 , wherein the metal insert is cast to the stud body. 
     
     
         21 . The traction element of  claim 11 , wherein the metal insert is mechanically coupled to the stud body. 
     
     
         22 . The traction element of  claim 11 , wherein the light weight filler material comprises nylon.