A sole structure for an article of footwear may include a chamber for receiving a pressurized fluid, the chamber having a first chamber barrier layer and a second chamber barrier layer bonded to the first chamber barrier layer about peripheral portions of the first chamber barrier layer and the second chamber barrier layer to define an interior void between the first chamber barrier layer and the second chamber barrier layer. The sole structure may also include a tensile member bonded to, and extending between, the first chamber barrier layer and the second chamber barrier layer. The sole structure may include a bond inhibiting material located between the tensile member and the first chamber barrier layer, the tensile member and the first chamber barrier layer being unbonded in an unbonded area in which the bond inhibiting material is disposed. The chamber may include an outwardly extending bulge in the unbonded area.

An article of footwear includes an upper comprising a knitted component forming a one-piece integrally knit element that forms a lower portion of the upper and extends from the lower portion toward a collar. The lower portion of the upper is configured to extend under a wearer's foot. The article of footwear includes an insert member having a bottom side with a plurality of protuberances that extend away, and the lower portion of the upper is vacuum molded around at least some portions of the protuberances of the insert member. The article of footwear may also include a sole assembly secured to the bottom side of the lower portion of the upper.

A sole assembly for footwear includes a base plate and at least two sole pods disposed adjacent one another but spaced apart by a gap. The sole pods define respective apertures that form an integral truss in each. The apertures can be aligned and parallel with one another and/or a longitudinal axis of the base plate and sole assembly. The truss system of the respective pods can independently deform to provide underfoot cushioning, but also can conform around and absorb underfoot terrain features. A method of manufacturing the sole assembly can include forming the sole pods adjacent one another in a planar configuration, rotating each of the sole pods to an upright configuration and joining those sole pods to one another but separating them from one another with a gap.

A process and system allow for rapid customization and fabrication of the midsole layer of a shoe for the mass manufacturing of shoes with custom midsoles. A partially manufactured shoe is made, a style is selected by the wearer, and a custom midsole is rapidly designed, and incorporated in the partially manufactured shoe style selected by the wearer. Also, in some shoes, reorganization relocates the midsole to the interior of the shoe during manufacturing.

An article of footwear has a midsole assembly that includes a fluid-filled bladder element having a substantially arc-shaped heel portion and having a lateral arm portion and a medial arm portion spaced from the lateral arm portion. Each of the arm portions extend from the heel portion. The bladder element is configured to be positioned with the heel portion in the heel region of midsole assembly, and the arm portions extending from the heel region to a forefoot region along a peripheral region. A method of manufacturing and a mold assembly for such an article of footwear are provided.

This document discloses a process for manufacturing recyclable injection molded microcellular foams for use in, footwear components, seating components, protective gear components, and watersport accessories. The process includes the steps of providing a thermoplastic polymer which comprises at least one monomer derived from depolymerized post-consumer plastic, inserting a fluid into a barrel of a molding apparatus. The fluid is introduced under temperature and pressure conditions to produce a super critical fluid. The process further includes mixing the thermoplastic polymer and super critical fluid so as to create a single phase solution, and injecting the single phase solution into a mold of an injection molding machine under gas counter pressure. The process further includes foaming the single phase solution by controlling the head and temperature conditions within the mold.

A method of forming a composite article includes constructing a preform having a strand layer including an interior portion and a peripheral portion surrounding the interior portion. The strand layer includes a plurality of strand segments traversing the interior portion and defining a first strand segment population density and a second strand segment population density. The preform is inserted into the mold cavity so that the interior portion of the preform is received in a molding region of the mold cavity. The molding region has a first thickness corresponding to the first strand segment population density and a second thickness corresponding to the second strand segment population density. Following the inserting, the mold is closed and the interior portion of the preform is compressed within the molding region. In the closed mold, the peripheral portion of the strand layer may be maintained in a loose state within the relief region.

Physical foaming a footwear component with a single-phase solution of a polymeric composition and a supercritical fluid is provided. The method include temperature conditioning a mold and then engaging the mold with a robot that conveys the mold to a press. At the press a gas counter pressure is applied to a cavity of the mold before injecting a single-phase solution of a polymeric composition and a supercritical fluid into the cavity of the mold. The process continues with releasing the gas counter pressure from the cavity of the mold and then removing the footwear component from the cavity of the mold. The parameters of the method are configured for the formation of the footwear component in an automated manner.

A method of forming a plate for an article of footwear is disclosed. The method includes applying a first strand portion to a base layer including positioning adjacent segments of the first strand portion to form a first layer on the base layer. The adjacent segments of the first strand portion having a greater density across a width of the plate between a medial side and a lateral side at a midfoot region of the plate than at a forefoot region of the plate and at a heel region of the plate. The method also includes applying at least one of heat and pressure to the first strand portion and to the base layer to conform the first strand portion and the base layer to a predetermined shape.

An article of footwear can comprise: an upper, and a sole assembly connected to the upper to form a receptacle for a human foot, the sole assembly can comprise: a cushion comprising an exterior wall that forms an enclosure; an antenna disposed within the enclosure; and a microchip connected to the antenna. A method of manufacturing an article of footwear can comprise: positioning an electronic communication device between two plies of polymer laminate; heating the two plies of polymer laminate to form a weld area and a cushion area, wherein the electronic communication device becomes encapsulated between the two plies of polymer laminate, inflating the cushion area with a gas; and sealing the cushion area.