Footwear cleat with cushioning
View Patent ↗A cleat for footwear. The cleat includes a base layer that attaches to the outsole of the footwear, a cushioning layer and a traction element layer. The traction element layer is attached to the base layer solely by the cushioning layer. Each of the cleat layers provides friction with the ground when the cleat engages the ground. The durometer of the base layer and the durometer of the traction element layer are greater than the durometer of the cushioning layer. When a user steps on a surface wearing a shoe outfitted with these cleats, the resilience 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 transmitted through the shoe's outsole. The user's comfort is thereby enhanced.
1. A shoe comprising:
an outsole including at least one ground-engaging cleat,
the at least one ground-engaging cleat having an outer surface portion that comes into contact with turf, the at least one ground-engaging cleat comprising:
a base layer characterized by a top portion and a bottom portion,
a cushioning layer, the top portion of the cushioning layer attached to the bottom portion of the base layer; and
a traction element layer, the traction element layer attached to the bottom portion of the cushioning layer,
wherein:
(1) the at least one ground-engaging cleat is attached to the shoe such that each of the base layer, the cushioning layer and the traction element layer extends to and partially defines the outer surface portion and can provide friction with the turf during ground engagement of the cleat,
(2) the durometer of the cushioning layer ranges from 65 to 80 on the Shore A scale and the durometer of cushioning layer is less than the durometer of the base layer and the durometer of the cushioning layer is less than the durometer of the traction element layer,
(3) the cushioning layer alone fastens the traction element layer to the bottom portion of the base layer,
(4) the base layer, the cushioning layer and the traction element layer are made of plastic materials,
(5) the base layer, the cushioning layer and the traction element layer are formed by injection molding, with either or both of the base layer and the traction element layer being formed before the cushioning layer being formed, and the cushioning layer then being formed by injection molding against one or both of the base layer and the traction element layer, and
(6) the outsole is over-molded onto a portion of the base layer to lock the at least one ground-engaging cleat into the outsole, while leaving the outer surface portion exposed to permit contact with the turf by each of the base layer, the cushioning layer and the traction element layer.
2. A shoe according to claim 1 wherein the durometer of the traction element layer is not less than 80 on the Shore A scale.
3. A shoe according to claim 1 wherein the shape of the ground engaging portion of the at least one ground-engaging cleat is one of conical, rectangular, pyramidal and frusto-conical.
4. A shoe according to claim 1 wherein the at least one ground-engaging cleat includes a shoe attachment element in the base layer and the shoe attachment element retains the at least one cleat in the outsole.