An adhesive composition for use in a shoe outsole assembly, and methods of forming the same are provided. In one aspect, the adhesive composition has a fabric layer with an adhesive applied to a top surface. In another aspect, the adhesive composition has a fabric layer with a barrier layer applied to a top surface, and an adhesive is applied to the barrier layer opposite to the fabric layer. The shoe outsole formed using the adhesive composition has the fabric material directly bonded with the outsole material such that the outsole material partially penetrates into the fabric. An adhesive is applied to the opposite side of the fabric or to the optional barrier layer which is on the opposite side of the fabric. This adhesive may then be used to bond the outsole to a shoe, such as a shoe upper, shoe midsole, and the like.

The invention concerns a method of producing an article of footwear comprising: providing an upper; providing a mold and opening the mold; inserting the upper into the open mold; closing the mold; and injecting a pressurized molten resin, wherein, after the injecting, there is a gap filled with the resin between a side wall of the mold and an outer surface of at least a first portion of the upper, wherein the gap is essentially zero at a contacting point, wherein the gap increases gradually from the contacting point in at least a first region of the mold.

The invention concerns a method of producing an article of footwear comprising: providing an upper; providing a mold and opening the mold; inserting the upper into the open mold; closing the mold; and injecting a pressurized molten resin, wherein, after the injecting, there is a gap filled with the resin between a side wall of the mold and an outer surface of at least a first portion of the upper, wherein the gap is essentially zero at a contacting point, wherein the gap increases gradually from the contacting point in at least a first region of the mold.

A method for manufacturing three-dimensional items with flexible walls is provided, by method of a mold and counter-mold between which a volume corresponding to that of the item to be obtained is delimited. The item is made up of laminar parts which are mounted on a template that is fixed to the inner surface of the mold. The laminar parts are joined to one another by means of a material which is injected in molten state through a network of conduits delimited between the counter-mold, template and the facing edges of adjacent laminar parts. The template is made of an elastically deformable material and has a three-dimensional configuration.

A method for manufacturing three-dimensional items with flexible walls is provided, by method of a mold and counter-mold between which a volume corresponding to that of the item to be obtained is delimited. The item is made up of laminar parts which are mounted on a template that is fixed to the inner surface of the mold. The laminar parts are joined to one another by means of a material which is injected in molten state through a network of conduits delimited between the counter-mold, template and the facing edges of adjacent laminar parts. The template is made of an elastically deformable material and has a three-dimensional configuration.

An example article includes a baffle to be inserted into a mold cavity of a mold for a midsole of an article of footwear. The baffle is to divide the mold cavity into a first sub-cavity and a second sub-cavity. The baffle is to isolate a first material injected into the first sub-cavity from a second material injected into the second sub-cavity. The second material has a differing material property to the first material.

An example article includes a baffle to be inserted into a mold cavity of a mold for a midsole of an article of footwear. The baffle is to divide the mold cavity into a first sub-cavity and a second sub-cavity. The baffle is to isolate a first material injected into the first sub-cavity from a second material injected into the second sub-cavity. The second material has a differing material property to the first material.

A production process of an insole, the steps of: cleaning an insole mold; spraying an oily release agent into a cavity of an upper mold and a cavity of a lower mold of the mold; uniformly fixing cloth in the cavity of the upper mold; injecting shoe material into the cavity of the lower mold of the mold, covering the upper mold of the mold to lock the upper mold and the lower mold after finishing injecting shoe material, and then placing the mold in an oven for baking, opening the upper mold of the mold after finishing baking, and taking out the insole. The production process of an insole is simple in process and high in yield rate, and uses the characteristics that the cloth and the raw material have good adhesion to directly put the cloth into the mold to take shape, thereby eliminating a glue adhesion process.

A production process of an insole, the steps of: cleaning an insole mold; spraying an oily release agent into a cavity of an upper mold and a cavity of a lower mold of the mold; uniformly fixing cloth in the cavity of the upper mold; injecting shoe material into the cavity of the lower mold of the mold, covering the upper mold of the mold to lock the upper mold and the lower mold after finishing injecting shoe material, and then placing the mold in an oven for baking, opening the upper mold of the mold after finishing baking, and taking out the insole. The production process of an insole is simple in process and high in yield rate, and uses the characteristics that the cloth and the raw material have good adhesion to directly put the cloth into the mold to take shape, thereby eliminating a glue adhesion process.

An article of footwear has an upper that is direct attached with the sole in a article of footwear mold. The sole has a film extending up sidewalls of the sole to a film edge that is prior to the sidewall and the upper joining. Method of manufacture of the article of footwear includes steps of positioning a film over a mold cavity and then securing the film to the mold. The film is heated and then drawn into the mold cavity under a vacuum. The film forms a liner of the mold cavity. A foam composition is injected into the lined mold cavity. As the foam composition expands, the foam composition interacts with and mechanically engages with the upper that is poisoned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper.