Article of footwear having a plate

Abstract

A component for a sole structure of an article of footwear includes a base layer including a substrate material and defining a longitudinal axis, a first fiber layer disposed on the base layer, and a second fiber layer disposed on the first fiber layer. The first fiber layer defines a first fiber array that is disposed at a first angle relative to the longitudinal axis. The second fiber layer defines a second fiber array that is disposed at a second angle relative to the longitudinal axis. The base layer, the first fiber layer, and the second fiber layer are printed to form the component, and the component is at least partially received within the sole structure and spaced apart from an insole of the footwear.

We claim: 
     
         1 . A component for a sole structure of an article of footwear, comprising:
 a base layer including a substrate material and defining a longitudinal axis,   a first fiber layer disposed on the base layer, the first fiber layer defining a first fiber array that is disposed at a first angle relative to the longitudinal axis; and   a second fiber layer disposed on the first fiber layer, the second fiber layer defining a second fiber array that is disposed at a second angle relative to the longitudinal axis;   wherein the base layer, the first fiber layer, and the second fiber layer are printed to form the component, and wherein the component is at least partially received within the sole structure and spaced apart from an insole of the footwear.   
     
     
         2 . The component of  claim 1 , wherein the first angle is different from the second angle. 
     
     
         3 . The component of  claim 2 , wherein the first fiber layer and the second fiber layer include a fiber material that comprises at least one of a carbon fiber, an aramid fiber, a boron fiber, or a glass fiber. 
     
     
         4 . The component of  claim 2 , wherein the first fiber array includes a first plurality of turns arranged along a portion of a periphery of the component. 
     
     
         5 . The component of  claim 4 , wherein the second fiber array includes a second plurality of turns arranged along a periphery of the component. 
     
     
         6 . The component of  claim 1 , wherein the component is printed layer-by-layer and treated in a compression mold, and wherein a transparent resin is applied to the component within the compression mold. 
     
     
         7 . The component of  claim 6 , wherein the base layer is configured to be removable. 
     
     
         8 . The component of  claim 1 , wherein the component extends within at least one of a forefoot region, a midfoot region, or a heel region of the footwear. 
     
     
         9 . The component of  claim 8 , wherein the component is at least partially exposed on a side of the sole structure. 
     
     
         10 . The component of  claim 8 , wherein the component is entirely concealed within the sole structure. 
     
     
         11 . The component of  claim 8 , wherein a portion of the component is configured to contact the insole. 
     
     
         12 . The component of  claim 11 , wherein the portion of the component is disposed within the heel region of the footwear. 
     
     
         13 . A plate for a sole structure of an article of footwear, the footwear comprising an upper having an insole, the plate comprising:
 a plurality of composite layers, each of the composite layers comprising a substrate material and a fiber material,   wherein each of the composite layers includes a fiber array, and   wherein the plate is printed layer-by-layer to define a top side and a bottom side, at least a portion of the top side being spaced apart from the insole of the upper.   
     
     
         14 . The plate of  claim 13 , wherein the fiber array is oriented at an angle that differs between adjacent composite layers. 
     
     
         15 . The plate of  claim 13 , wherein the composite layers are arranged as a stack between a top side and bottom side of the plate and the stack has quasi-isotropic properties. 
     
     
         16 . The plate of  claim 15 , wherein each of the composite layers has anisotropic properties, the anisotropic properties being different between adjacent composite layers. 
     
     
         17 . The plate of  claim 16 , wherein the anisotropic properties include at least one of a bending resistance, a torsional resistance, or a tensile stiffness. 
     
     
         18 . The plate of  claim 13 , wherein the fiber material includes at least one of carbon fibers, aramid fibers, boron fibers, or glass fibers. 
     
     
         19 . The plate of  claim 13 , wherein the plate includes an anterior segment having a first stiffness, an arch segment having a second stiffness, and a posterior segment having a third stiffness. 
     
     
         20 . The plate  claim 19 , wherein the first stiffness is greater than the second stiffness and the third stiffness is greater than the first stiffness. 
     
     
         21 . The plate of  claim 19 , wherein the first stiffness, the second stiffness, and the third stiffness are equal. 
     
     
         22 . The plate of  claim 13 , wherein the plate defines a periphery that extends from a toe end to a heel end, and wherein a plurality of peripheral elements are arranged along a portion of the periphery. 
     
     
         23 . The plate of  claim 22 , wherein the plurality of peripheral elements comprise the fiber material. 
     
     
         24 . The plate of  claim 23 , wherein each fiber array includes a plurality of turns arranged along the periphery and engaged with the plurality of peripheral elements. 
     
     
         25 . The plate of  claim 13 , wherein the plate extends within at least one of a forefoot region, a midfoot region, or a heel region of the footwear. 
     
     
         26 . The plate of  claim 25 , wherein the plate is at least partially exposed on a side of the sole structure. 
     
     
         27 . The plate of  claim 25 , wherein the plate is entirely concealed within the sole structure. 
     
     
         28 . The plate of  claim 25 , wherein a portion of the plate is configured to contact the insole. 
     
     
         29 . The plate of  claim 28 , wherein the portion of the plate is disposed within the heel region of the footwear. 
     
     
         30 . The plate of  claim 25 , wherein a portion of the plate is configured to contact an outsole. 
     
     
         31 . The plate of  claim 30 , wherein the portion of the plate is disposed within the forefoot region of the footwear.