ATHLETIC FOOTWEAR AND CLEAT SYSTEMS AND METHODS
Athletic footwear and cleats comprise a first molded layer comprising a rigid substrate including a hole for connecting the molded layer to a shoe, and wherein the first molded layer is adapted to engage binding elements of a pedal, and a second molded layer formed on the bottom portion of the first molded layer, the second molded layer substantially conforming to a shape of a portion of the first molded layer. The second molded layer forms a soft walking surface adapted to provide traction with a walking surface and a raised portion formed thereon, the raised portion adapted to impact float friction during operation. The first molded layer may include nylon, and the second molded layer comprises a thermoplastic elastomer, a thermoplastic polyurethane, and/or a silicone substrate. A third molded layer may be provided to reduce contact friction between the cleat and the pedal of an exercise cycle.
1 . A cleat comprising:
a first molded layer comprising a rigid substrate, wherein the first molded layer forms a hole for connecting the molded layer to a shoe, and wherein the first molded layer is adapted to engage binding elements of a pedal; and
a second molded layer formed on a bottom portion of the first molded layer, the second molded layer substantially conforming to a shape of a portion of the first molded layer.
2 . The cleat of claim 1 , wherein the second molded layer forms a walking surface.
3 . The cleat of claim 1 , wherein the second molded layer comprises a soft substrate having friction properties to produce traction on slippery surfaces and/or a textured surface.
4 . The cleat of claim 1 , wherein the second molded layer includes a raised portion formed thereon, the raised portion adapted to impact float friction during operation.
5 . The cleat of claim 1 , wherein the first molded layer comprises nylon.
6 . The cleat of claim 1 , wherein the second molded layer comprises a thermoplastic elastomer (TPE), a thermoplastic polyurethane (TPU), and/or a silicone substrate.
7 . The cleat of claim 1 , wherein the first molded layer and the second molded layer are formed through an injection molding process.
8 . The cleat of claim 1 , further comprising a third molded layer adapted to reduce contact friction between the cleat and the pedal.
9 . The cleat of claim 8 , wherein the third molded layer comprises Teflon.
10 . The cleat of claim 1 , wherein the cleat is further adapted for use on an exercise cycle.
11 . A method comprising:
injecting a hard substrate into a first mold to generate a first molded layer comprising a rigid substrate, including forming a hole in the hard substrate for connecting the molded layer to a shoe, and wherein the first molded layer is adapted to engage binding elements of a pedal; and
injecting a soft substrate to generate a second molded layer formed on a bottom portion of the first molded layer, the second molded layer substantially conforming to a shape of a portion of the first molded layer.
12 . The method of claim 11 , further comprising forming a walking surface on the second molded layer.
13 . The method of claim 11 , further comprising forming a surface on the second molded layer adapted to produce traction on slippery surfaces, the second molded layer comprising a soft substrate having friction properties to produce traction on slippery surfaces and/or a textured surface.
14 . The method of claim 11 , further comprising forming raised portion in the second molded layer, the raised portion adapted to impact float friction during operation.
15 . The method of claim 11 , wherein injecting a hard substrate into a first mold comprises injecting nylon.
16 . The method of claim 11 , wherein injecting a soft substrate to generate the second molded layer comprises injecting a thermoplastic elastomer (TPE), a thermoplastic polyurethane (TPU), and/or a silicone substrate.
17 . The method of claim 11 , wherein the first molded layer and the second molded layer are formed through an injection molding process comprising a single mold.
18 . The method of claim 11 , further comprising injecting a low friction substrate to generate a third molded layer adapted to reduce contact friction with the pedal.
19 . The method of claim 18 , wherein the low friction substrate comprises Teflon.
20 . The method of claim 11 , further comprising creating a mold for a cleat adapted for use with an exercise cycle.