Tooling and components of an injection-molding system may be used to mold a foam article. The tooling and components may include features that control parameters of the injection-molding and foaming process, such as temperature, pressure, shot size, shot placement, and the like.

A process for manufacturing a multi-layered sole directly on the upper, of the type that employs the technique known as “direct injection on the upper”, by which soles are made of a plastic material and consist of a plurality of layers with different colour, density, softness and physical-mechanical properties. Said layers form at least an external sole, called “outsole”, an internal sole, called “insole” that adheres and extends only partially or totally on the surface of the upper, and an intermediate sole, called “midsole”, that is intended to hold the other two above-said soles. Said process provides for the use of a single mould which is brought, when suitably equipped, in a well-defined sequence, in front of at least three distinct injectors (I.sub.1, I.sub.2, I.sub.3) in order to obtain, also in sequence, by at least a first moulding operation (P.sub.1) the lower portion of the sole, i.e. the “outsole”, by at least a second moulding operation (P.sub.2) the upper part of the sole, i.e. the “insole” and by at least a third moulding operation (P.sub.3) the “midsole”.

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.

Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding, or injection molding followed by compression molding.

Tooling and components of an injection-molding system may be used to mold a foam article. The tooling and components may include features that control parameters of the injection-molding and foaming process, such as temperature, pressure, shot size, shot placement, and the like.

Sole structures including a plate including a first polyolefin resin, and an edge portion comprising a second resin are disclosed herein. The edge portion is more flexible or less rigid than the plate. Articles of footwear formed from the sole structures are also provided. Methods of making the polyolefin resin compositions, plates, edge portions, sole structures, and articles of footwear are also provided. In some aspects, the first polyolefin resin composition includes an effective amount of a polymeric resin modifier.

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.

Tooling and components of an injection-molding system may be used to mold a foam article. The tooling and components may include features that control parameters of the injection-molding and foaming process, such as temperature, pressure, shot size, shot placement, and the like.

In certain aspects, the inventive subject matter is directed to production of constructs of footwear and components thereof by jet extrusion. The inventive subject matter contemplates novel processes for making such constructs using jets or streams of materials that solidify as fibers, and which form into two- or three-dimensional webs as they are collected. The webs may be in the nature of films, membranes, or mats. In some embodiments, the inventive subject matter generally relates to nonwoven textiles consisting of webs of superfine fibers, i.e., fibers with diameters in nanoscale or micronscale ranges.

An article of apparel or sporting equipment, such as garments and footwear incorporates a molded component formed of a UV radiation curable material. In the case of an article of footwear, the UV radiation curable material may be formed into an outsole. The method of manufacturing such articles include placing an ultraviolet radiation curable material in contact with a molding surface; conforming the UV radiation curable material to a shape of the molding surface, forming a molded component; and removing the molded component from the molding surface, such that the component maintains the shape of the molding surface. The molded component may be exposed to ultraviolet radiation in an amount and for a duration that is sufficient to partially cure or fully cure the UV radiation curable material.