Sole for article of footwear having detachable traction elements and method of manufacturing thereof

Abstract

A sole for an article of footwear, the sole comprising a midsole including a top midsole surface and a bottom midsole surface, the bottom midsole surface defining an indentation. The sole comprises a carbon fiber sole plate including a top plate surface attached to the bottom midsole surface, a bottom plate surface configured to contact a ground surface, and a forefoot plate area, the bottom plate surface defining a cavity. The sole comprises a mounting receptacle disposed within the cavity, and a traction element configured to detachably couple to the mounting receptacle. A sole for an article of footwear, the sole comprising a holding plate including a top holding surface attached to a recess of a bottom midsole surface of a midsole, wherein the holding plate defines a cavity. The sole comprises a carbon fiber sole plate and a mounting receptacle disposed within the cavity.

What we claim is: 
     
         1 . A sole for an article of footwear, comprising:
 a midsole comprising a top midsole surface and a bottom midsole surface, the bottom midsole surface defining an indentation;   a carbon fiber sole plate comprising a top plate surface attached to the bottom midsole surface, a bottom plate surface configured to contact a ground surface, and a forefoot plate area, the bottom plate surface defining a cavity;   a mounting receptacle disposed within the cavity; and   a traction element configured to detachably couple to the mounting receptacle.   
     
     
         2 . The sole for the article of footwear of  claim 1 , wherein the top plate surface defines a convex structure in the forefoot plate area, the convex structure being received by the indentation in the midsole. 
     
     
         3 .- 4 . (canceled) 
     
     
         5 . The sole for the article of footwear of  claim 1 , wherein the bottom plate surface defines the cavity in the forefoot plate area. 
     
     
         6 . The sole for the article of footwear of  claim 1 , wherein the mounting receptacle comprises a first fastener. 
     
     
         7 .- 8 . (canceled) 
     
     
         9 . The sole for the article of footwear of  claim 1 , wherein the midsole further comprises a forefoot midsole area, and wherein the bottom midsole surface defines the indentation in the forefoot midsole area of the midsole. 
     
     
         10 . The sole for the article of footwear of  claim 1 , wherein the carbon fiber sole plate further comprises a midfoot plate area and a heel plate area, and wherein the midfoot plate area extends between the forefoot plate area and the heel plate area. 
     
     
         11 . (canceled) 
     
     
         12 . The sole for the article of footwear of  claim 1 , wherein the carbon fiber sole plate further comprises at least one layer comprising carbon fibers and a resin. 
     
     
         13 . The sole for the article of footwear of  claim 1 , wherein the bottom plate surface defines a secondary traction element in the forefoot plate area. 
     
     
         14 . (canceled) 
     
     
         15 . The sole for the article of footwear of  claim 1 , wherein the mounting receptacle comprises an outer surface engaged with a sidewall of the cavity within which the mounting receptacle is disposed, and wherein the sidewall retains the mounting receptacle. 
     
     
         16 . (canceled) 
     
     
         17 . The sole for the article of footwear of  claim 1 , wherein the mounting receptacle comprises a bottom surface configured to contact the ground surface, and wherein the bottom surface of the mounting receptacle is flush with the bottom plate surface. 
     
     
         18 . The sole for the article of footwear of  claim 1 , wherein the traction element comprises a projection protruding from the mounting receptacle away from the bottom plate surface. 
     
     
         19 .- 21 . (canceled) 
     
     
         22 . A method of fabricating a sole for an article of footwear, the method comprising:
 forming a carbon fiber sole plate comprising a top plate surface, a bottom plate surface configured to contact a ground surface, a forefoot plate area, a midfoot plate area, a heel plate area, and a mounting receptacle;   attaching the carbon fiber sole plate to a midsole comprising a top midsole surface and a bottom midsole surface; and   detachably coupling a traction element to the mounting receptacle of the carbon fiber sole plate.   
     
     
         23 . The method of  claim 22 , wherein forming the carbon fiber sole plate further comprises:
 placing one or more shaped layers into a sole plate mold, wherein at least one of the one or more shaped layers comprises one or more sublayers comprising carbon fibers, glass fibers, glass fleece prepreg, and/or resin.   
     
     
         24 .- 27 . (canceled) 
     
     
         28 . The method of  claim 22 , wherein detachably coupling the traction element to the mounting receptacle of the carbon fiber sole plate further comprises:
 detachably coupling the traction element to the mounting receptacle of the carbon fiber sole plate before or after the forming of the carbon fiber sole plate.   
     
     
         29 . A sole for an article of footwear, comprising:
 a midsole comprising a top midsole surface and a bottom midsole surface, the bottom midsole surface defining a recess;   a holding plate comprising a top holding surface and a bottom holding surface, wherein the top holding surface is attached to the recess of the bottom midsole surface, and wherein the holding plate defines a cavity;   a carbon fiber sole plate comprising a top plate surface and a bottom plate surface, wherein the top plate surface is attached to both the bottom midsole surface and the bottom holding surface, and wherein the bottom plate surface is configured to contact a ground surface;   a mounting receptacle disposed within the cavity; and   a traction element configured to detachably couple to the mounting receptacle.   
     
     
         30 . (canceled) 
     
     
         31 . The sole for the article of footwear of  claim 29 , wherein the mounting receptacle comprises a bottom surface configured to contact the ground surface, and wherein the bottom surface of the mounting receptacle is flush with at least one of the bottom plate surface or a portion of the bottom holding surface. 
     
     
         32 . The sole for the article of footwear of  claim 29 , wherein at least a portion of the bottom holding surface surrounding the mounting receptacle is configured to contact the ground surface, and wherein the portion of the bottom holding surface is flush with the bottom plate surface. 
     
     
         33 . The sole for the article of footwear of  claim 29 , wherein the bottom midsole surface defines an indentation disposed within the recess, and wherein the top holding surface defines a convex structure received by the indentation. 
     
     
         34 .- 35 . (canceled) 
     
     
         36 . The sole for the article of footwear of  claim 29 , wherein the carbon fiber sole plate defines an opening extending between the top plate surface and the bottom plate surface and wherein the opening receives at least a portion of the traction element. 
     
     
         37 .- 43 . (canceled) 
     
     
         44 . A method of fabricating a sole for an article of footwear, the method comprising:
 forming a holding plate comprising a top holding surface, a bottom holding surface, and a mounting receptacle;   attaching the holding plate to a midsole comprising a top midsole surface and a bottom midsole surface, wherein the bottom midsole surface defines a recess in a forefoot midsole area of the midsole, and wherein the holding plate is disposed within the recess;   forming a carbon fiber sole plate comprising a top plate surface, a bottom plate surface configured to contact a ground surface, a forefoot plate area, a midfoot plate area, and a heel plate area;   attaching the carbon fiber sole plate to the midsole and the holding plate, wherein the top plate surface of the carbon fiber sole plate is attached to the bottom midsole surface and the bottom holding surface; and   detachably coupling a traction element to the mounting receptacle of the holding plate.   
     
     
         45 .- 50 . (canceled)