An article of footwear flat pattern upper (126, 300, 302) portion (216) is provided. The upper portion (302) has a midline reference line (415, 416) extending between the toe end apex (316) and a midpoint on the heel end (314). The upper portion (302) also is comprised of an origin (344) aperture that is located within 10 millimeters of the midline reference line (415, 416) between the toe end (306) and the heel end (314) of the upper portion (302). The upper portion (302) is also formed with an overlay (500) that is coupled with the upper portion (302) between the toe end (306) and the heel end (314) and between the medial side (315) and the lateral side (317). The overlay (500) has an alignment aperture (345) that is aligned with the origin (344) aperture.

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.

An insole for insertion into an article of footwear to alleviate foot pain and a related method of manufacture is disclosed. The multi-layer insole comprises a top layer, a textured layer and a bottom layer. The top layer having first and second impression portions, wherein the first impression conforms to the muscle anatomy and the second impression conforms to the tendon anatomy of the plantar side of the user's foot. The bottom layer having a third impression portion that conforms to a user's skeletal anatomy on the plantar side of the foot. A method of forming the multi-layer insole utilizes a pair of blanks for accepting the foot at different pressures to form negative impressions of the plantar side of the foot. The top and bottom layers of the multi-layer footwear insole are then formed from the negative impressions.

A method of forming a sole assembly of an article of footwear including an interior space and an exterior surface includes providing a first portion of the sole assembly. The first portion includes a first surface that at least partially defines the interior space and a first chamber surface that opposes the first surface. The first portion is made from a first material. The method also includes providing a second portion of the sole assembly that includes a second surface that at least partially defines the exterior surface of the article of footwear and a second chamber surface that opposes the second surface. The second portion is made from a second material that is different from the first material. The method additionally includes operably securing the first and second portions such that the first chamber surface and the second chamber surface cooperate to at least partially define a chamber.

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.

A strobel for an article of footwear comprises a polymeric bladder that defines an interior cavity. The polymeric bladder is configured to retain a fluid in the interior cavity. The polymeric bladder has a peripheral flange extending around at least a portion of a perimeter of the interior cavity. The peripheral flange defines a groove extending along the peripheral flange. The polymeric bladder may include a first polymeric sheet bonded to a second polymeric sheet at the peripheral flange and joined to the second polymeric sheet at a plurality of interior welds. Methods of manufacturing a strobel and manufacturing footwear are included.

Aspects hereof relate to a multi-part mold for molding articles of footwear having sole regions of differing materials forming a desired outsole surface material pattern. The multi-part mold includes a carrier mold portion and a tray mold portion. The carrier mold portion provides definition to the lateral surfaces of a resultant co-molded product. The tray mold portion cooperates with the carrier mold portion and provides definition to another (e.g., bottom) surface of the resultant co-molded product. The tray mold portion generally includes at least one pod or cavity for receiving a first material that when cured/catalyzed, defines a patterned other (e.g., bottom) surface of the resultant product. A multi-part mold having the structure as described herein permits interchangeability of multiple tray mold portions with a single carrier mold portion.

The present invention is a method for manufacturing inflatable bladders for use in articles of manufacture. The method includes the steps of providing a first polymer film, applying a curable release coating to the polymer film in a pattern that corresponds to the configuration of the inflatable bladder, curing the release coating to the first polymer film, providing a second polymer film with the first polymer film to form a layered element such that the release coating is disposed between the polymer films, positioning the layered element between two plies of material, applying heat and pressure to adhere the polymer films together except in the area where the release coating has been applied to form an inflatable compartment surrounded by a sealed perimeter, and removing the plies of material from the adhered first and second polymer films.

A method of manufacturing a midsole includes placing first and second preforms into a midsole recess of a mold, with first and second portions of the mold defining a first overflow chamber connected to the first recess; closing the mold by positioning the first and second portions in contact with one another; heating the mold for a predetermined period of time at a predetermined temperature such that the first and second preforms melt and bond together to form a midsole, with a portion of each of the first and second preforms flowing into the first overflow chamber to form a first overflow portion; removing the midsole from the mold; allowing the midsole to expand; and cutting away the first overflow portion.

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.