The present invention is a composite sole used in footwear. The composite sole comprises of two components, a foot support that suspends the foot and a structural chassis. The foot support is a flexible material that attaches to the perimeter of the structural chassis and conforms to the foot. The structural chassis provides rigidity and the foot support provides sufficient strength to suspend the foot during rigorous physical activity. The chassis and foot support performs similarly to that of a trampoline; however, its function has a plurality of features not found in a trampoline. The structural chassis is designed to provide a multitude of physical and performance characteristics in the heel, arch, forefoot and toe area to assist in pronation, plantar support, energy return, upper shoe comfort, toe-off and cushion at impact. The structural chassis has air vents, allowing air to enter and the foot support includes perforations allowing this air to ventilate the underside of foot.

A reinforcement structure is disposed on a midsole of a shoe. A first bar extends from a first point in a medial side of the midsole to a second point in the medial side of the midsole. The second point is closer to a toe of the shoe than the first point. A second bar extends from a third point in the medial side of the midsole to a fourth point in a lateral side of the midsole. The fourth point being closer to the toe of the shoe than the third point. A third bar extending from a fifth point in the medial side of the midsole to a sixth point in the lateral side of the midsole. The sixth point being closer to the toe of the shoe than the fifth point. The third bar extending further toward the toe of the shoe than the second bar.

The present invention provides a method for making a sole structure with a knitted fabric and a sole structure. The method comprises steps of: placing a thermoplastic filling material in a knitted fabric, sealing an opening of the knitted fabric, placing the knitted fabric with the opening sealed in a mold, applying a heating temperature to melt the thermoplastic filling material of the knitted fabric, and restricting a shape of the knitted fabric via the mold to make a sole structure. The sole structure includes a compressible elastomer and a knitting texture wrapped around the compressible elastomer and fused with a surface of the compressible elastomer. The compressible elastomer is formed from the thermoplastic filling material after being melted and cooled. The knitting texture is formed from the knitted fabric and is capable of being directly observed from an appearance of the sole structure.

A shoe basically includes an upper and a sole. The sole is attached to the upper. The sole includes an outsole and a first midsole. The first midsole has a fore part, a first heel part, a second heel part and a boundary part. The first heel part is at least partly disposed along a longitudinal centerline of the shoe and configured to support a center part of a heel. The second heel part is disposed laterally outward of the longitudinal centerline of the shoe and configured to support an outer part of the heel. The boundary part is provided between the first heel part and the second heel part such that the first heel part and the second heel part are movable relative to one another.

Systems and methods are disclosed including a tri-layer orthotic system having a heel portion and a forefoot portion to support respective heel and forefoot portions of a foot through at least a portion of a gait cycle. The tri-layer orthotic system can include an upper layer suspended over a mid-layer and a base layer to create a rear spring section, a mid-spring section, and a front spring section. A distal toe portion of the mid-layer can form the forefoot portion of the tri-layer orthotic system and a heel upper layer portion of the upper layer can form the heel portion of tri-layer orthotic system.

A footwear construction includes a sole assembly having a convoluted lower surface with multiple rolling peaks and valleys, and first and second midsoles having different durometers to provide dynamic stability, cushion and/or traction. The second midsole can include apertures that extend into some peaks so those peaks are compressible and conform well to underfoot terrain. The sole assembly can include certain lateral or medial peaks that transition to a perimeter of the sole assembly, and that are of a truncated shape with a sidewall to provide firmness and/or rigidity to the sole assembly around the perimeter. Other peaks can be disposed inward from the lateral or medial peaks and can be of a lesser firmness so those central peaks can provide cushioning and/or macro traction capabilities. A related method of manufacture also is provided.

An article of footwear includes a strobel, a footwear upper, and a sole plate. The strobel includes a polymeric bladder defining an interior cavity and configured to retain a fluid in the interior cavity. The polymeric bladder has a peripheral flange extending around a perimeter of the interior cavity from a medial side to a lateral side of the polymeric bladder at a front of the polymeric bladder. The footwear upper is secured to the peripheral flange. The sole plate has a heel portion, a midfoot portion, and a forefoot portion, and a rear extent of the strobel is secured to the sole plate or to the footwear upper forward of a rear extent of the sole plate. A method of manufacturing the article of footwear includes securing the peripheral flange to the upper.

A midsole for an article of footwear including a three dimensional mesh including interconnected unit cells and methods of making the same. The interconnected unit cells each include a plurality of struts defining a three dimensional shape. The interconnected unit cells are connected at nodes having a valence number defined by the number of struts connected at that node. The valence number of the nodes may vary to provide customized characteristics to zones or portions of the midsole. The plurality of interconnected unit cells may be organized in a warped cubic lattice structure. The warped cubic lattice structure and the size/shape of interconnected unit cells may vary to provide customized characteristics to zones or portions of the midsole. The three dimensional mesh may be customized based on a biometric data profile for an individual, or group of individuals. The midsole may be manufactured using an additive manufacturing process.

A shoe includes a sole with a midsole, and an upper portion joined to the sole. The midsole includes a cut having a linear shape, and a depth from a first height position to a second height position in a thickness direction. The cut is configured such that a part of the cut has no contact point with an other part of the cut, and the cut forms a V shape at the deepest part on a cross section when opposite inner walls of the cut are spaced from each other.

An article of footwear includes a sole structure and an upper that is attached to the sole structure. The upper defines a cavity that is configured to receive a foot of a wearer. The upper is at least partially defined by a textile. The textile includes a first area that is substantially smooth. The first area defines a reference boundary that conforms to the cavity. The textile includes a second area. The second area includes a plurality of projection structures that project away from the reference boundary and outwardly from the cavity at varying heights. The second area includes a plurality of recess structures that recess away from the reference boundary and inwardly toward the cavity. The plurality of projection structures and the plurality of recess structures are in an alternating arrangement across the textile.