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.

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.

An article of footwear is provided having an elevated plate structure incorporated in the sole structure and optionally including a fluid-filled chamber. The elevated plate structure can include an upper plate and a plurality of legs extending downward toward the outsole. End portions of the legs can engage an upper region of the outsole. The elevated plate structure can form a cage region that can optionally include a fluid-filled chamber substantially disposed therein. The elevated plate structure can further include a lower plate disposed at an upper region of the outsole, which can form a lower portion of the cage region. Portions of the legs can be integrated with impact-attenuating members in the heel region in various configurations and can provide features for the impact-attenuating members, such as support, impact-attenuation and adjustable impact-attenuation features.

Provided is a method for producing a resin molded article including an introducing step of introducing a plurality of resin foam particles and a heat medium substance into a forming mold, and a molding step of, after the introducing step, heating the forming mold to a temperature at which the heat medium substance can be vaporized, thereby obtaining a resin molded article including the plurality of resin foam particles.

The present invention is directed to articles of manufacture having at least a portion The present invention is directed to articles of manufacture (and a method for forming such an article) having at least a portion prepared using high coefficient friction material as an interface for human contact using, but not limited to, polymeric materials. The articles may be incorporated into any product or any portion of a product where non-slip properties are required during human contact and usage. Preferably, a thermoplastic material such as thermoplastic urethane with very durable but soft properties is accurately texturized to achieve optimum frictional properties for a given application. The textures are carefully calculated for the desired friction characteristics. The invention further provides methods of preparing articles made with the interface that are characterized by their excellent economic benefits, ease of use, environmental benefits and functional advantages.

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 forefoot region of the plate than at a midfoot 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.

A method of manufacturing an article comprises etching an etched feature on a surface of a first polymeric sheet, and forming a fluid-filled bladder element from the first polymeric sheet, with the fluid-filled bladder element having a sealable internal cavity that retains fluid. The method includes assembling the bladder element in the article so that a first portion of the bladder element having the etched feature is exposed to view, and a second portion of the bladder element is blocked from view by the article. An article includes the bladder element with the etched feature.

A sole structure for an article of footwear includes an upper layer formed of a first foam material and a lower layer formed of a second foam material and having a hardness that is greater than a hardness of the upper layer. In addition, a plate can be disposed between the upper layer and the lower layer, where the plate has a hardness that is greater than each of the upper and lower layers.

Described herein is a 3D spacer fabric reinforced composite, a process for producing it, a method of using it in footwear, and a footwear including it.

Provided is a method for manufacturing a porous midsole the method including: a cotton-beating step (S1) of forming a midsole base (10) having porous voids 16 by mixing low melting fibers (12) and high melting fibers (14); and a thermoforming step (S2) of bonding and fixing the high melting fibers into a compressed state by the melt adhesive strength of the low melting fibers (12) by compressively thermoforming the midsole base (10) at a melting point temperature of the low melting fibers (12).