A comfort system for Cowboy and work boots, including an insole chassis, an insole chassis backing board, and cushioning pads for absorbing and attenuating shocks encountered by a wearer of the boots. Cushioning pads are secured to a surface of the insole chassis backing board, and apertures in the insole chassis allow the cushions to pass through. Additional cushioning pads are retained in recesses in the midsole. Pads on insole chassis backing board and midsole are vertically aligned. A steel toe inset is utilized in conjunction with the comfort system for work boots. A rim may depend below the midsole to receive a foamed plastic pad.

A method for forming a plate includes attaching a first strand portion to a flexible substrate to form a first layer on the substrate and positioning a second strand portion on the first layer to form a second layer on the first layer in a plurality of discrete regions on the substrate. The method also includes positioning a plurality of traction elements into corresponding cavities formed into a first mold surface and positioning the substrate on the first mold surface to change a shape of the substrate. At least one of heat and pressure is applied to the first strand portion, the second strand portion, the substrate, and the traction elements to conform the substrate to the shape of the first mold surface and form the traction elements into the substrate at each of the discrete regions. The method also includes incorporating the substrate into an article of footwear.

A method of forming a decorated midsole element for articles of footwear includes obtaining a decorated film having one or more graphic elements applied to a first surface of the film and placing the decorated film in a mold. A midsole element is obtained and placed in the mold, and pressure is applied to the mold to form a midsole element having a decorated surface. The decorated film may include a layer of polyether-block co-polyamide polymer and the midsole element may be formed of ethylvinylacetate. A midsole assembly and an article of footwear having decorated midsole top layers are also described.

A method of manufacturing a midsole includes placing first and second preforms into a midsole recess of a mold, with first and second portions of the mold defining a first overflow chamber connected to the first recess; closing the mold by positioning the first and second portions in contact with one another; heating the mold for a predetermined period of time at a predetermined temperature such that the first and second preforms melt and bond together to form a midsole, with a portion of each of the first and second preforms flowing into the first overflow chamber to form a first overflow portion; removing the midsole from the mold; allowing the midsole to expand; and cutting away the first overflow portion.

A midsole or insole device for a shoe includes a first variable stimulation mechanism positioned to interface one of the metatarsal heads and the heel and a second variable stimulation mechanism positioned to interface a lateral aspect of the foot between the fifth metatarsal head and the heel. During gait-related activities, the first variable stimulation mechanism produces stimulus of an intensity greater than the second variable stimulation mechanism. At least one of the first variable stimulation mechanism and the second variable stimulation mechanism comprises two bonded layers including a resilient stimulating upper layer and a less resilient stimulus-enhancing lower layer. The upper layer includes a plurality of holes that pass through the entirety of the upper layer, and the lower layer includes a plurality of equally spaced upwardly facing projections aligned substantially perpendicular to an upper surface of the upper layer.

A sole structure includes a midsole component including a midsole body, a plurality of traction members, and a securing layer. The midsole body defines an outer midsole surface and an inner midsole surface opposite the outsole midsole surface. The traction members are coupled to the midsole body. Each of the traction members includes a base and a traction body protruding from the base away from the inner midsole surface. The traction body extends through the midsole body, and the base abuts the inner midsole surface. As such, that the traction members are movable relative to the midsole body. The securing layer is disposed over the base, and is coupled to the inner midsole surface to hold the plurality of traction members in contact with the midsole component.

A sole structure for an article of footwear having an upper includes an outsole defining a first aperture, a cushioning member disposed on the outsole and defining a second aperture, and a plate disposed between the cushioning member and the upper. The plate includes an anterior-most point disposed in a forefoot region, a posterior-most point disposed closer to a heel region than the anterior-most point, a metatarsophalangeal (MTP) point disposed between the anterior-most point and the posterior-most point, and an anterior curved region having a radius of curvature extending through the forefoot region and a mid-foot region and including a forefoot curved portion extending from the MTP point to the anterior-most point and a mid-foot curved portion extending from the MTP point toward the posterior-most point. Overlapping portions of the first aperture and the second aperture expose a region of the plate.

A method of manufacturing a midsole for an article of footwear includes placing first and second preforms in a first mold, closing and heating the first mold to produce a midsole preform with a peripheral preform flange, removing the midsole preform from the first mold and allowing it to further expand and cool, placing the midsole preform in a second mold, with a volume of a midsole recess of the second mold being less than a volume of the midsole preform, and a volume of a peripheral recess of the second mold being less than a volume of the peripheral preform flange, closing the second mold thereby compressing the midsole preform and the peripheral preform flange, and heating the second mold to form a midsole with a peripheral flange, allowing the second mold to cool, opening the second mold, and cutting away a peripheral flange of the midsole.

Articles of footwear and soles are disclosed. The article of footwear may include an upper, a midsole with a midsole core and a midsole rim, and an outsole. The midsole core may be manufactured from a plurality of portions that are arranged in a particular order before being placed in a mold. The plurality of portions may be arranged so that the portions at least partially overlap each other. The plurality of portions may be arranged in longitudinal strips. The plurality of portions may be arranged in lateral portions. The plurality of portions may be adhered to each other before being placed in the mold. The mold may apply heat and pressure for a predetermined amount of time to form the midsole.

A method of manufacturing a midsole includes placing first and second preforms into a midsole recess of a mold, with first and second portions of the mold defining a first overflow chamber connected to the first recess; closing the mold by positioning the first and second portions in contact with one another; heating the mold for a predetermined period of time at a predetermined temperature such that the first and second preforms melt and bond together to form a midsole, with a portion of each of the first and second preforms flowing into the first overflow chamber to form a first overflow portion; removing the midsole from the mold; allowing the midsole to expand; and cutting away the first overflow portion.