An article of footwear comprises a sole structure having a cushioning component defining an enclosed, fluid-filled chamber. The cushioning component has a top wall, a bottom wall, a medial side wall at a medial side of the article of footwear, and a lateral side wall at a lateral side of the article of footwear. The cushioning component includes a unitary outsole having a bottom portion, a medial side portion, and a lateral side portion. The bottom portion is bonded to the bottom wall, the medial side portion is bonded to the medial side wall, and the lateral side portion is bonded to the lateral side wall. A method of manufacturing includes disposing the first and second polymer sheets and the outsole in a mold assembly and thermally bonding the outsole to the second polymer sheet, and the first and second polymer sheets to one another to form a chamber.

A footwear injection mold includes a primary injection mold having a first coupling element of a first coupling assembly; and a secondary injection mold provides at least part of an injection chamber for molding a footwear part. The injection chamber has a proximal surface defining at least part of a distal surface of the footwear part and a second coupling element of the first coupling assembly. The first coupling assembly is configured to fix the secondary injection mold relative to the first injection mold.

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 EVA sole having an upper face and a bottom, comprising an inscribed channel and a plurality of recesses positioned on the upper face, a TPU material disposed of within the inscribed channel, and a nylon stabilizer, which is bonded to the upper face inside of the inscribed channel.

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.

An insulated sole having down feather insulation held captive therein and method of fabrication is described. The sole is formed with open top end cavities in which there is disposed down feathers or mixtures thereof to capture and retain heat. A membrane seals the open top end of the cavities. The insulated sole is used in the fabrication of articles of footwear for use in cold weather climate to resist to the cold emanating from the ground to shield against heat loss from the wearer's feet.

Improved soles and insoles for shoes, in particular sports shoes, are described. In an aspect, a sole for a shoe, in particular a sports shoe, with at least a first and a second surface region is provided. The first surface region comprises expanded thermoplastic polyurethane (“TPU”). The second surface region is free from expanded TPU.

This disclosure concerns a master model for the production of a mold, comprising: (a) a first part, a second part comprising a textured surface; wherein the first part and the second part are connected.

An article of footwear includes a sole assembly that has a bladder element with a first outer surface and a second outer surface opposite the first surface. A guide component is fused to one of the outer surfaces. The guide component has at least one groove extending laterally across the guide component. The at least one groove is configured to receive and guide at least one elongated member such that the elongated member is movable lengthwise when positioned in the at least one groove. A method of manufacturing a sole assembly for an article of footwear includes fusing the guide component to one of the first outer surface and the second outer surface of the bladder element.

A method of forming a sole assembly of an article of footwear that includes an interior space that receives a foot of a wearer is disclosed. The article of footwear also includes an exterior surface. The method includes providing a first portion of the sole assembly. The first portion includes a first surface that at least partially defines the interior space. The first portion also includes a first chamber surface that opposes the first surface. Moreover, the method includes providing a second portion of the sole assembly. The second portion includes a second surface that at least partially defines the exterior surface of the article of footwear. The second portion also includes a second chamber surface that opposes the second surface. The method further includes operably securing the first portion to the second portion such that the first chamber surface and the second chamber surface cooperate to at least partially define a substantially sealed chamber within the sole assembly.