Molded rubber objects may be molded and de-molded by defining both a desired final form for the molded rubber object and a tab extending from the final form of the molded rubber object using a cavity in a mold. Rubber pellets may be dispensed in predetermined amounts at desired location(s) within the cavity to provide the rubber needed to form the molded rubber object. Heat and pressure may be applied to the mold to cause the rubber pellets to fill the cavity defining both the desired final form of the molded rubber object and the tab. After the heat and pressure has been applied, a gripping device may grasp the tab and move the tab in a direction and with sufficient force to peel the rubber object from the mold cavity. If desired, the tab may be removed from the molded rubber object.

A method of forming three-dimensional composite comprising steps of: (a) manufacturing at least one shaping member; (b) fitting each of the at least one shaping member on each of at least one mold; (c) adhering at least one connection sheet on said each shaping member so as to form each of at least one semi-finished product; (d) fixing said each semi-finished product in a cavity; and (e) heating said each semi-finished product and vacuuming the cavity. Said shaping member has at least one orifice and covers said each mold, and each connection sheet has a substrate and an adhesive layer, a melting point of the adhesive layer is less than the substrate. Said each semi-finished product in the cavity is heated until the adhesive layer melts, and the cavity is vacuumed so that the adhesive layer penetrates into said each shaping member, thus producing a three-dimensional finished product.

The present invention relates to a thermoforming mold for EVA, comprising an upper aluminum mold and a lower aluminum mold, both of which are hinged and each provided with a handle, wherein, the upper aluminum mold is provided with a raised pattern, and the lower aluminum mold is provided with a sunken cavity, characterized in that an upper passage passing through the inside of the pattern is provided inside the upper aluminum mold, a lower passage passing through the bottom of the cavity is provided inside the lower aluminum mold, the upper passage has a first opening in the inner surface of the upper aluminum mold, the lower passage has a second opening corresponding to and communicated with the first opening in the inner surface of the lower aluminum mold, and both sides of the lower passage are provided with a vapor/water inlet and a vapor/water outlet respectively.

Described are soles for a shoe having a region with a plurality of pellets, each pellet having a hollow core structure. The plurality of pellets are formed of a composite material comprising a base layer and an outer layer. The base layer is formed of a material having a first melting temperature, and the outer layer is formed of a material having a second melting temperature. The first melting temperature is greater than the second melting temperature, and the plurality of pellets are bonded through melting of the outer layers while the inner layers retain the hollow core structure without melting.

Foam items may be buffed using particles such as particulate sodium bicarbonate in accordance with the present invention. Foam items may be, for example, expanded EVA foam items pre-formed into an intermediate size and shape. A skin layer may be formed during the expansion of the foam item to form an expanded foam item which may be entirely or partially removed by buffing the item using particles projected with selected buffing parameters. The buffing parameters may be varied based upon the thickness of at least a portion of the skin layer and/or the desired degree of moldability for the foam item after buffing. Particulate sodium bicarbonate or other types of particles used for buffing may be recycled and reused for further buffing of foam items.

The invention relates to parts having a foamed polymeric material attached to a fabric, and systems and methods for forming same. An example method of attaching foamed polymeric material to a fabric layer includes providing a mold having at least one cavity and at least one material injection channel in fluid communication with the cavity, disposing a fabric over the at least one cavity, closing the mold, injecting unfoamed polymeric material into the at least one cavity through the material injection channel, wherein the unfoamed polymeric material penetrates at least a portion of the fabric proximate the at least one cavity to attach the polymeric material to the fabric layer, and foaming the unfoamed polymeric material.

Described are methods for the manufacture of a plastic component, in particular a cushioning element for sports apparel, a plastic component manufactured with such a method, for example a sole or a part of a sole for a shoe, and a shoe with such a sole. According to an aspect of the invention, a method for the manufacture of a plastic component, in particular a cushioning element for sports apparel, is provided which includes loading a mold with a first material which includes particles of an expanded material, and, during loading the mold, pre-heating the particles by supplying energy, wherein the energy is supplied in the form of at least one electromagnetic field.

Methods for manufacturing at least a portion of an upper for an article of footwear that include thermo-forming a pattern on the upper. The methods may include disposing a skin for forming an upper over and inflatable bladder and disposing a mold insert between the skin and a surface of a mold cavity. The mold insert may include a mold pattern including surface features formed in the mold insert. The inflatable bladder may be inflated such that the skin is pressed against the mold insert within a heated mold cavity to form a pattern on an exterior surface of the skin and cause the skin to take on the shape of at least a portion of an upper. In some embodiments, the surface features may be disposed in a gradient pattern configured to provide varying degrees of one or more characteristics to different areas of an upper.

Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.

A method for manufacturing a shoe sole with multi-material spikes includes: providing a spike-forming mold which includes an upper mold and a lower mold, wherein the lower mold includes a first filling hole which is in communication with the first spike cavity, different materials are placed in the first spike cavity to form the multi-material spike; providing a first mold which includes a second spike cavity; providing a second mold which includes a second filling hole; assembling the first and second molds, together to form a sole cavity, wherein the multi-material spike is placed into the sole cavity, a sole material is filled into the sole cavity through the second filling hole, and then the multi-material spike and the sole material are adhered to each other by hot melting; and opening the first and second molds, and obtaining a shoe sole with the multi-material spike.