Joining a bottom unit, such as an athletic shoe sole, with an upper is achieved with an over molding process. A midsole core may be formed with a direct attach to an underfoot portion of the upper. The forming of the midsole core may be achieved with open cast molding or injection molding, for example. A shell may encapsulate the midsole core and also mechanically engage with the upper to further join the bottom unit with the upper. The shell and the midsole core may be formed from an elastomeric polymer such as polyurethane, thermoplastic polyurethane, ethyl-vinyl acetate, and/or silicone-based materials.

An integrally-formed shoe having no machine sewing and a manufacturing method thereof are provided. A structure of the shoe includes: a lining sock body that uses a knitting manner and includes an opening; and a surface sock body that uses a knitting manner and includes an opening and a sole, where the opening of the lining sock body is nested inside the surface sock body; the two sock bodies are properly mounted on a sock machine; low melting point yarn and nylon elastic filament are mixed into knitting of the lining sock body; low melting point yarn, nylon elastic filament, and set yarn are mixed into knitting of the surface sock body; after the sock machine weaves and molds the two sock bodies into a whole, a hollow mold is nested inside the surface sock body; the whole is heated and baked to slightly damage surface tissues of the yarn, and is then cooled to make the set yarn in knitwear be reorganized and extended according to the shape of an external fixing mold, to present a predetermined pattern; and after the surface sock body presents the predetermined pattern, the sole is directly bonded to the bottom of the surface sock body so as to achieve bonding of the sole and the surface sock body, to complete the integrally-formed shoe having no machine sewing, so that a user feels more comfortable due to no machine sewing.

An integrally-formed shoe having no machine sewing and a manufacturing method thereof are provided. A structure of the shoe includes: a lining sock body that uses a knitting manner and includes an opening; and a surface sock body that uses a knitting manner and includes an opening and a sole, where the opening of the lining sock body is nested inside the surface sock body; the two sock bodies are properly mounted on a sock machine; low melting point yarn and nylon elastic filament are mixed into knitting of the lining sock body; low melting point yarn, nylon elastic filament, and set yarn are mixed into knitting of the surface sock body; after the sock machine weaves and molds the two sock bodies into a whole, a hollow mold is nested inside the surface sock body; the whole is heated and baked to slightly damage surface tissues of the yarn, and is then cooled to make the set yarn in knitwear be reorganized and extended according to the shape of an external fixing mold, to present a predetermined pattern; and after the surface sock body presents the predetermined pattern, the sole is directly bonded to the bottom of the surface sock body so as to achieve bonding of the sole and the surface sock body, to complete the integrally-formed shoe having no machine sewing, so that a user feels more comfortable due to no machine sewing.

A method for joining a sole element with an upper element includes the steps of (a) operating a positioning system to position the sole element and the upper element in a defined first position with respect to each other, (b) operating the positioning system to position the sole element and the upper element in a second position for applying a joining agent to the sole element and/or the upper element and (c) joining the sole element with the upper element by operating the positioning system to position the sole element in contact with the upper element in a third position of the positioning system, wherein the third position is defined with respect to the first position.

A method for joining a sole element with an upper element includes the steps of (a) operating a positioning system to position the sole element and the upper element in a defined first position with respect to each other, (b) operating the positioning system to position the sole element and the upper element in a second position for applying a joining agent to the sole element and/or the upper element and (c) joining the sole element with the upper element by operating the positioning system to position the sole element in contact with the upper element in a third position of the positioning system, wherein the third position is defined with respect to the first position.

An article of footwear may have an upper and a sole structure secured to the upper. The sole structure has a plurality of support elements, and each of the support elements include a shell and a core. The shell defines an interior void and is formed from a polymer material that extends around substantially all of the void. The core has a shape of the void and is located within the void, with at least a portion of the core being a polymer foam material. The polymer foam material of at least two of the support elements may have different densities.

An article of footwear may have an upper and a sole structure secured to the upper. The sole structure has a plurality of support elements, and each of the support elements include a shell and a core. The shell defines an interior void and is formed from a polymer material that extends around substantially all of the void. The core has a shape of the void and is located within the void, with at least a portion of the core being a polymer foam material. The polymer foam material of at least two of the support elements may have different densities.

The present disclosure provides a shoe, comprising: a shoe sole having a bottom surface and an attachment surface opposite to the bottom surface; a plurality of positioning structures disposed on the perimeter of the attachment surface; and a foot covering part comprising at least one thread, in which each thread extends from one of the positioning structures to another positioning structure to form a thread extension part, and the collection of a plurality of thread extension parts forms a configuration that fits a user's foot. The present disclosure also provides a manufacturing method of a shoe. The foot covering part of the shoe of the present disclosure comprises one or a plurality of threads.

The present disclosure provides a shoe, comprising: a shoe sole having a bottom surface and an attachment surface opposite to the bottom surface; a plurality of positioning structures disposed on the perimeter of the attachment surface; and a foot covering part comprising at least one thread, in which each thread extends from one of the positioning structures to another positioning structure to form a thread extension part, and the collection of a plurality of thread extension parts forms a configuration that fits a user's foot. The present disclosure also provides a manufacturing method of a shoe. The foot covering part of the shoe of the present disclosure comprises one or a plurality of threads.

An article of footwear includes an upper and a strobel stitched to the upper at a series of stitches disposed in stitch holes that extend through the strobel. The strobel and the upper define a foot-receiving cavity with an inner surface of the strobel disposed at the foot-receiving cavity. A midsole is secured to the upper and an outer surface of the strobel is disposed at the midsole. The stitch holes are obstructed such that the stitch holes are not exposed to both the midsole and the foot-receiving cavity. Accordingly, when a flowable polymeric material is injected in a mold cavity to form the midsole with the lower portion of the upper and the strobel in the mold cavity, the stitch holes will not provide a path for entry of the flowable polymeric material into the foot-receiving cavity. A method of manufacturing an article of footwear is disclosed.