A method of forming a cushioning element. The method including placing a first sheet adjacent to an outer surface of a first mold portion, the first mold portion including a first mold cavity. The method including pressing a portion of the first sheet into the first mold portion and into the first mold cavity with a forming tool, wherein at least a portion of the forming tool is extended into the first mold cavity. The method including applying negative pressure to the first mold cavity to draw the portion of the first sheet into the first mold cavity, and joining a second sheet to the first sheet to form the cushioning element.

A method of forming a cushioning element. The method including placing a first sheet adjacent to an outer surface of a first mold portion, the first mold portion including a first mold cavity. The method including pressing a portion of the first sheet into the first mold portion and into the first mold cavity with a forming tool, wherein at least a portion of the forming tool is extended into the first mold cavity. The method including applying negative pressure to the first mold cavity to draw the portion of the first sheet into the first mold cavity, and joining a second sheet to the first sheet to form the cushioning element.

The present invention refers to a method for the manufacture of sporting goods, in particular shoes, comprising the steps of providing a plurality of components in one of a plurality of predefined shapes, and placing the plurality of components onto a two-dimensional or three-dimensional carrier surface to create the sporting good or a part thereof.

A method of reclaiming used tennis balls and transforming the material reclaimed from the tennis balls into soles for footwear. This multi-step process requires acquiring used tennis balls, grinding the tennis balls into ground rubber bits (usable elements) and tennis ball fuzz (unusable elements). The rubber and fuzz are passed through a screen which allows the rubber bits to exit the screen but retains the fuzz. The rubber is then mixed with an H.sub.2O and Polyurethane mixture to form a rubber mixture. This mixture is then pressed to a desired thickness in a hydraulic press, cured, and then cut out into a desired shoe sole shape and size which can be used to manufacture footwear.

A method of reclaiming used tennis balls and transforming the material reclaimed from the tennis balls into soles for footwear. This multi-step process requires acquiring used tennis balls, grinding the tennis balls into ground rubber bits (usable elements) and tennis ball fuzz (unusable elements). The rubber and fuzz are passed through a screen which allows the rubber bits to exit the screen but retains the fuzz. The rubber is then mixed with an H.sub.2O and Polyurethane mixture to form a rubber mixture. This mixture is then pressed to a desired thickness in a hydraulic press, cured, and then cut out into a desired shoe sole shape and size which can be used to manufacture footwear.

Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.

Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.

A sole structure for an article of footwear is provided. The sole structure includes a first midsole portion, a second midsole portion, and a sheet. The first midsole portion includes a first sidewall. The second midsole portion includes a second sidewall. The sheet is disposed between the first midsole portion and the second midsole portion and extends from the first sidewall and the second sidewall. The sheet extends at least partially over the second sidewall.

A sole structure for an article of footwear is provided. The sole structure includes a first midsole portion, a second midsole portion, and a sheet. The first midsole portion includes a first sidewall. The second midsole portion includes a second sidewall. The sheet is disposed between the first midsole portion and the second midsole portion and extends from the first sidewall and the second sidewall. The sheet extends at least partially over the second sidewall.

Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding, or injection molding followed by compression molding.