A healthcare footwear article includes an upper shoe body and a sole member provided underneath the upper shoe body and is connected with the upper shoe body to form an integral body. The upper shoe body and the sole member is configured from a material consisting of approximately 70% to approximately 80% of silicon rubber by weight, approximately 5% to approximately 20% of negative ion powder by weight, approximately 2% to approximately 7% of antiwear agent by weight, approximately 5% to approximately 20% of titanium powder by weight, approximately 0.1% to approximately 1.5% of vulcanizing agent by weight, approximately 5% to approximately 10% of infrared ray powder by weight, and approximately 0.1% to approximately 8% of dye by weight.

A cushion device is provided comprising a plurality of cells arranged in an array. Each one of the plurality of cells may comprise a plurality of vertical walls interconnected to form a vertical structure. Each vertical wall of each cell may be connected to an adjacent vertical wall of an adjacent cell such that each cell is connected to a plurality of adjacent cells. Each of the plurality of vertical walls may comprise a port where the port of each vertical wall of each cell may be in fluid communication with an adjacent port of the adjacent vertical wall of the adjacent cell via a fluid aperture.

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 variety of devices for protecting a user's foot from injury are disclosed. In one instance, the device is an external metatarsal protection device for a shoe or boot, having a sole with a first surface for supporting a wearer's foot and a second surface for contacting a ground area, an upper affixed to the sole, and an integral toe cap. An interior surface of the upper and the first surface of the sole define a receptacle for receiving the wearer's foot. The external protection device is incorporated along an exterior surface of the upper and is positioned to protect at least a metatarsal region of the wearer's foot. In an instance, the external protection device has injection-molded first and second layers of material, with the cushioning elements formed on a surface of the first layer and a plurality of grooves defined on a surface of the second layer.

An insole may include an insole body in a shape receivable in a shoe; an electronic element provided in the insole body; a connection line configured to electrically connect to the electronic element and including a contact terminal exposed to the outside of the insole body; and a connector including a detachable member configured to at least partially protrude outward from the insole body and configured to support the contact terminal.

An inner sole board having varying regions of flexibility is provided for use in an article of footwear. The inner sole board may include different materials along its length at different locations that vary its flexibility. An inner sole board is manufactured in an injection molding process requiring only one mold. The process includes a first step of providing a mold, a second step of providing an injection molding assembly, a third step of preparing an injection molding assembly and mold, a fourth step of injecting material into the mold, and a fifth step of establishing the dimensions of a first portion. During the injection molding process, the flow rate of at least one material may be controlled by a nozzle gate to control the shape and size of the flex zone it creates. In this manner, the inner sole board may be customized for a specific sport or individual.

A shoe sole member formed by a foam includes cells having a certain size and being excellent in transparency in order to provide a shoe sole member being lightweight and excellent cushioning properties while having transparency.

An injection molding method includes providing a molding device including a first mold, a second mold over the first mold and a first mold cavity defined by the first mold and the second mold; injecting a first material into the first mold cavity; forming a first layer from the first material; replacing the second mold by a third mold, injecting a second material into a second mold cavity defined by the first mold and the third mold; and forming a second layer from the second material, wherein the second layer at least partially contacts the first layer. The first material is same as the second material.

Presented are manufacturing systems, methods, and devices for forming footwear using scrap or waste plastic materials. A method for manufacturing an article of footwear, such as an athletic shoe, begins with receiving a batch of recycled plastic, which may include thermoplastic elastomers or ethylene-vinyl acetate, and grinding the batch of recycled plastic material. The ground recycled material is processed, for example, by adding a foaming agent that activates at elevated temperatures. The processed recycled material is placed into the internal cavity of a final mold that is shaped like a segment of the footwear, such as a unitary sole structure. To form the footwear segment, the processed recycled material is heated past the threshold activation temperature of the foaming agent such that the foaming agent causes the recycled material to expand and fill the internal cavity of the final mold. The formed footwear segment is then extracted from the mold.

An injection molded integral multicolor thermoplastic elastomeric foamed sole, comprising an integral sole made from thermoplastic elastomeric foaming bodies of at least two colors, and on surfaces thereof are provided grains of arbitrarily superposed injection strips; the foamed sole is made by: mixing, milling and heating thermoplastic elastomer raw materials of at least two colors, lubricants, and foaming auxiliaries to be thermoplastic elastomeric fused-masses, adding respectively gas-foaming agents at 0.2%-10% of thermoplastic elastomeric raw materials, compressive injecting gas-foaming agents respectively into thermoplastic elastomeric fused-masses, fully mixing to form thermoplastic elastomeric gas foamed polymers, and extruding foaming strips of thermoplastic elastomeric gas polymers of the at least two colors with an extrusion and injection process and/or co-extruding the foaming strips of thermoplastic elastomeric gas polymers of the at least two colors by a co-extrusion process into molds to form arbitrarily superposed strips, clamp molds, discharge gas and form.