Footwear components are made from lightweight textile structures (e.g., including circular knitted structures made from natural or synthetic fibers, such as socks or sock-type structures). The textile structures are selectively supported at various areas to provide desired local characteristics. Additional aspects relate to methods of making such components, precursors to such components, and articles of footwear containing such components.

Footwear components are made from lightweight textile structures (e.g., including circular knitted structures made from natural or synthetic fibers, such as socks or sock-type structures). The textile structures are selectively supported at various areas to provide desired local characteristics. Additional aspects relate to methods of making such components, precursors to such components, and articles of footwear containing such components.

An anatomical insole for footwear which comprises in its entirety a one-piece padded body, wherein it has a thicker padded area in the form of a bubble in the area of the foot arch, a thicker padded area in the form of a bubble in the area which supports the metatarsals of the foot and a thicker padded area in the form of a bubble in the area located between the metatarsals and the toes of the foot.

Methods and systems are provided for forming a molded foam article. An example method may include molding a plurality of separate pieces of closed-cell foam by exposure to a temperature cycle within a sealed mold to soften the plurality of pieces sufficiently for physical bonding; and forming a molded foam article with the pieces bonded together without an adhesive, wherein, during the temperature cycle, the mold is unsealed at least once to release gases and/or pressure. In another example, a method includes exposing a filled, sealed mold filled with a plurality of pieces of foamed material to a heating cycle; at a threshold temperature, unsealing the filled, sealed mold until a pressure reduces to within a threshold of atmospheric pressure; and, following the unsealing, cooling the filled mold prior to removing a molded foam article.

Methods and systems are provided for forming a molded foam article. An example method may include molding a plurality of separate pieces of closed-cell foam by exposure to a temperature cycle within a sealed mold to soften the plurality of pieces sufficiently for physical bonding; and forming a molded foam article with the pieces bonded together without an adhesive, wherein, during the temperature cycle, the mold is unsealed at least once to release gases and/or pressure. In another example, a method includes exposing a filled, sealed mold filled with a plurality of pieces of foamed material to a heating cycle; at a threshold temperature, unsealing the filled, sealed mold until a pressure reduces to within a threshold of atmospheric pressure; and, following the unsealing, cooling the filled mold prior to removing a molded foam article.

A footwear assembly having an upper that comprises a neoprene sock with a foot portion integrally connected to a leg portion. The foot portion has heel, vamp and under-foot portions. The leg portion has front shin, side wall, and rear calf-side portions. The upper has a unitary, outer, injection molded layer molded directly onto the foot and shin portions of the neoprene sock, while the sidewall and rear calf-side portions remain substantially uncovered by the injection molded layer. The injection molded layer encases the foot portion of the neoprene sock. The injection molded layer on the shin portion defines a shin guard portion having a necked down area integrally connected to the injection molded layer at the vamp portion, wherein the shin guard extends upwardly from the necked-down portion in an outwardly diverging shape away from the vamp.

A footwear assembly having an upper that comprises a neoprene sock with a foot portion integrally connected to a leg portion. The foot portion has heel, vamp and under-foot portions. The leg portion has front shin, side wall, and rear calf-side portions. The upper has a unitary, outer, injection molded layer molded directly onto the foot and shin portions of the neoprene sock, while the sidewall and rear calf-side portions remain substantially uncovered by the injection molded layer. The injection molded layer encases the foot portion of the neoprene sock. The injection molded layer on the shin portion defines a shin guard portion having a necked down area integrally connected to the injection molded layer at the vamp portion, wherein the shin guard extends upwardly from the necked-down portion in an outwardly diverging shape away from the vamp.

A shoe mold structure contains: a base, a lower part, an upper part, a mold core, and two connecting rod assemblies. The base includes a movable space, and the lower part includes a lower cavity, a through orifice, and two guiding slots. The upper part includes an upper cavity and at least one feeding orifice, and a connecting face of the upper part and the lower part flushes with a connection section of a body and a sole of a shoe. The mold core includes a molding portion, an extension, a holding plate, and two guide plates, wherein the extension extends to the movable space from the molding portion via the through orifice. Each connecting rod assembly couples with each of the two side surfaces of the upper part and said each guide plate.

A goalie skate assembly has i) a plastic blade mounting member adapted to releasably receive a metal skate blade therein, and ii) a monocoque carbon fiber and resin composite skate boot body for receiving a foot of the user therein. The unitary structure of the skate boot body includes i) a sole portion, ii) a heel portion extending upwardly from the sole portion for receiving a heel of the user therein, iii) a pair of side portions extending upwardly from opposing sides of the sole portion, and iv) a lower portion extending downwardly from a bottom side of the sole portion so as to surround at least a portion of the blade mounting member. A toe cap mounted on the skate boot body includes a molded plastic outer shell and a liner formed of a fiber and resin composite material bonded to an inner surface of the outer shell.

A goalie skate assembly has i) a plastic blade mounting member adapted to releasably receive a metal skate blade therein, and ii) a monocoque carbon fiber and resin composite skate boot body for receiving a foot of the user therein. The unitary structure of the skate boot body includes i) a sole portion, ii) a heel portion extending upwardly from the sole portion for receiving a heel of the user therein, iii) a pair of side portions extending upwardly from opposing sides of the sole portion, and iv) a lower portion extending downwardly from a bottom side of the sole portion so as to surround at least a portion of the blade mounting member. A toe cap mounted on the skate boot body includes a molded plastic outer shell and a liner formed of a fiber and resin composite material bonded to an inner surface of the outer shell.