An article of footwear has an upper that is direct attached with the sole. 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 positioned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper. The film is then trimmed from the sole sidewalls.

A footwear moulding system for direct injection production of footwear includes a supporting mould, a last, an in-mould, and an injection channel. The supporting mould includes at least an in-mould support. The in-mould is elastomeric and the in-mould includes an in-mould outer surface configured to be supported by said in-mould support. The in-mould support includes at least one support side mould and a support bottom mould.

An article of footwear has an upper that is direct attached with the sole. 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 positioned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper. The film is then trimmed from the sole sidewalls.

An injection-molding process for injecting a shoe soling including at least two adjacent injection-molding layers onto a shoe upper drawn over a shoe last, uses a mold cavity including a frame, the cavity being covered at the top by the upper also serving as a mold cover, with plastic material being injected into the cavity below the upper. To produce two adjacent injection-molding layers of plastic materials having different properties and reaction times in one operation, i.e. without needing an interim mold opening, before covering the cavity a film is clamped over it by a clamp mounted on the frame. When filling the cavity, the space below the film is first filled with plastic material to produce the first injection-molding layer and then, to produce the adjacent second injection-molding layer, the space above the film is filled with plastic material. Plastic materials are used that inseparably attach to the film.

A last for forming an upper of an article of footwear includes an exterior surface, where the exterior surface includes a plurality of three dimensional structural surface components disposed over at least 50% of the exterior surface of the last.

A shoe comprising a sole and an upper secured to the sole. The sole has a lower sole member, a heel member, a shank member, a heel cushion, and a foot pad. The heel member extends downwardly from the lower sole member. The heel member includes a heel outer peripheral surface and an open top heel cavity. The lower sole member includes a top surface and a lower sole cavity extending downwardly from the top surface. The shank member has a shank midfoot portion and a shank heel portion. The shank midfoot portion is in the lower sole cavity and the shank heel portion is in the heel cavity. The heel cushion is in the heel cavity. The shank heel portion is sandwiched between the heel cushion and the heel member.

A footwear article forming process, and a device for the same are disclosed. The process includes: providing a forming mold set including an outer modular mold, an inner formation mold, and a footwear-forming space therebetween. The footwear-forming space comprises a footwear lower portion forming space and a footwear main portion forming space. Footwear article forming steps are as follows: injecting a pre-determined amount of a footwear main portion rubber material into a footwear main portion sprue channel, the footwear main portion rubber material being injected from a footwear main portion rubber injection opening into the footwear main portion forming space via a transfer injection channel; and placing a footwear lower portion rubber material into the footwear lower portion forming space.

The present invention relates to a mould (10) for producing footwear (1) by direct injection onto an upper (2) of a sole (3), comprising a tread (5) and a midsole (4), wherein the midsole (4) is composed of a first layer (6) and a second layer (7). The mould (10) comprises a base (12), a pair of first half-rings (16), a lid (18), a pair of second half-rings (20) and a mould last (22). The first half-rings (16) are designed to be arranged close together such that they abut against the base (12) and against the lid (18), so as to form a first mould cavity for moulding the first layer (6) of the midsole (4). While the first half-rings (16) are abutting against the base (12), the second half-rings (20) are designed to be arranged close together, such that they lie over the half-rings (16) and abut against the upper (2), fitted onto the mould last (22), so as to form a second mould cavity for moulding the second layer (7) of the midsole (4). In accordance with the invention the first half-rings (16) are provided with guiding means (24) so that they can be moved away from and towards each other and rotate about an axis of rotation (C). The invention also relates to a method for producing footwear by direct injection onto an upper, which may be performed by means of the mould according to the invention.

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 injected footwear with internal complex graphic is a footwear apparatus that also is an easily manufacturable product. The footwear apparatus includes a sole, an upper, at least one complex graphic, and a sock liner. The sole is below the wearer's foot, while the upper covers the rest of the wearer's foot. The complex graphic integrates an aesthetically pleasing element for the footwear apparatus. The sock liner is used as an intermediate between the wearer's foot and the rest of the footwear apparatus. The complex graphic is internalized in between the sock liner and the upper. The upper and the sole are specifically made of the injectable molding material. A proximal portion of the sock liner is attached to the complex graphic, while the injectable molding material is bonded to a surrounding portion of the sock liner.