The present invention provides a method for manufacturing shoes having springs embedded therein, the method in which comfort and body weight distribution effect can be enhanced by means of the shock-absorbing force of resilient members being more effectively transmitted to the soles of a wearer.

A boot form for a hockey skate is made of multiple plastic materials having different hardness properties, or different flexural moduli, and is formed via an injection-molding process or another similar process. One or more of the plastic materials may be reinforced with fibers of glass, carbon, aramid, or another stiffening material to strengthen one or more regions of the boot form. For example, pellets of a first plastic material having a flexural modulus of approximately 190 MPa (e.g., a polyamide elastomer block amide) may be injected into a mold to form a softer upper region of the boot form. And pellets of a second plastic having a flexural modulus of approximately 20,000 MPa (e.g., a Nylon 12 with long glass fibers) may be injected into the mold to form a stiffer lower region of the boot form. Additional skate components may then be attached to the boot form.

A method of manufacturing an article of footwear includes cutting a plurality of sipes into an outer surface of a pre-formed, foamed thermoplastic sole structure that has both an inner surface and an opposite outer surface. An adhesive is then applied to the inner surface of the pre-formed sole structure and the sole structure is heated to permit forming. The heated sole structure is positioned adjacent to a ground-facing surface of a lasted upper, and then is thermoformed against the lasted upper to draw the adhesive into contact with the ground-facing surface of the upper, and such that at least a portion of the pre-formed sole structure bends into contact with a sidewall of the upper.

An article of footwear flat pattern upper (126, 300, 302) portion (216) is provided. The upper portion (302) has a midline reference line (415, 416) extending between the toe end apex (316) and a midpoint on the heel end (314). The upper portion (302) also is comprised of an origin (344) aperture that is located within 10 millimeters of the midline reference line (415, 416) between the toe end (306) and the heel end (314) of the upper portion (302). The upper portion (302) is also formed with an overlay (500) that is coupled with the upper portion (302) between the toe end (306) and the heel end (314) and between the medial side (315) and the lateral side (317). The overlay (500) has an alignment aperture (345) that is aligned with the origin (344) aperture.

A method of making a foamed article, for example a foamed component for an article or footwear, comprises forming a structure of interconnected, unfoamed, thermoplastic polymeric members spaced to define openings between the thermoplastic polymeric members. The structure may be made by printing a thermoplastic polymeric material with a three-dimensional printer. The thermoplastic polymeric members are heated to a first temperature to soften the thermoplastic polymeric members and the softened thermoplastic polymeric members are infused with at least one inert gas at a first pressure greater than atmospheric pressure. The first pressure is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymeric members. After being infused with the inert gas, the pressure is reduced to at least partially foam the thermoplastic polymeric members.

A method of making a foamed article, for example a foamed component for an article or footwear, comprises forming a structure of interconnected, unfoamed, thermoplastic polymeric members spaced to define openings between the thermoplastic polymeric members. The structure may be made by printing a thermoplastic polymeric material with a three-dimensional printer. The thermoplastic polymeric members are heated to a first temperature to soften the thermoplastic polymeric members and the softened thermoplastic polymeric members are infused with at least one inert gas at a first pressure greater than atmospheric pressure. The first pressure is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymeric members. After being infused with the inert gas, the pressure is reduced to at least partially foam the thermoplastic polymeric members.

Described is a shoe upper for a shoe, in particular an athletic shoe, wherein the shoe upper is laceless and comprises: (a.) a lateral portion; (b.) a medial portion; and (c.) at least an elastic intermediate portion between the lateral portion and the medial portion, wherein the stiffness of at least one of the lateral portion and the medial portion is at least 2 times higher than the stiffness of the elastic intermediate portion.

A footwear moulding system for direct injection production of footwear, said footwear moulding system comprising a supporting mould (21), a last (30), an in-mould (22), and an injection channel (40),
wherein the supporting mould (21) comprises at least an in-mould support.

The in-mould (22) is elastomeric and the in-mould (22) comprises an in-mould outer surface (76) configured to be supported by said in-mould support.

The in-mould support comprises at least one support side mould (26, 28) and a support bottom mould (24).

Further, the invention relates to a direct injection footwear production method for footwear by use of such a moulding system.

A plate for an article of footwear includes a substrate, a first strand portion attached to the substrate via first stitching, and a second strand portion disposed on the first layer. The first strand portion includes first segments that each extend between two different locations along the substrate to form a first layer on the substrate. The second strand portion includes second segments that each extend between two different locations along the substrate to form a second layer on the first layer.

An article of footwear has an upper that is direct attached with the sole. The sole has a film extending up sidewalls of the sole to a film edge that is prior to the sidewall and the upper joining. Method of manufacture of the article of footwear includes steps of positioning a film over a mold cavity and then securing the film to the mold. The film is heated and then drawn into the mold cavity under a vacuum. The film forms a liner of the mold cavity. A foam composition is injected into the lined mold cavity. As the foam composition expands, the foam composition interacts with and mechanically engages with the upper that is positioned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper. The film is then trimmed from the sole sidewalls.