Joined fiber-reinforced composite material assembly with tunable anisotropic properties

A method of forming a wearable protective plate assembly for use to protect against body movement beyond a constrained range of expected motion, the method comprising:

• forming a first layer of flexible material having a plurality of arranged fibers, wherein the first layer has a first rigidity, a first tensile modulus, and a first compressive modulus lower than the first tensile modulus, wherein the first layer is elastically bendable in a first direction with a surface being in compression, and in a second direction opposite the first direction with the surface being in tension;
• forming a second layer having a second rigidity greater than the first rigidity;
• fixedly coupling the second layer to the first layer in a substantially parallel orientation, wherein a plate assembly formed by the first layer and the second layer has a first bending stiffness during bending in the first direction and a second bending stiffness greater than the first bending stiffness during bending in the second direction;
• and
• incorporating the plate assembly in a user-wearable assembly to protect against user body movement beyond a constrained range of expected motion.

A method of forming a portion of an article of footwear, comprising:

• providing an anisotropic plate assembly comprising:
• an upper layer having a first rigidity, a first tensile modulus, and a first compressive modulus different than the first tensile modulus;
• a lower layer having a second rigidity greater than the first rigidity, and having a second tensile modulus and a second compressive modulus approximately equal to the second tensile modulus;
• and
• an intermediate layer arranged between the upper layer and the lower layer, wherein—
• the upper and lower layers are joined together at an interface area defined by the intermediate layer,
• the anisotropic plate assembly is elastically bendable in a first direction and a second direction opposing the first direction, and
• the anisotropic plate assembly has a first bending stiffness during bending in the first direction and a second bending stiffness greater than the first bending stiffness during bending in the second direction;
• and
• incorporating the anisotropic plate assembly into the footwear.