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.

In the present invention, a shoe sole member is composed of a foam that has a non-foamed film having a thickness of 50 μm or more on a lateral surface of the foam constituting at least a part of an outer peripheral surface of the shoe sole, in order to provide the shoe sole member composed of the foam having both stiffness and shock absorbing properties and provide a shoe excellent in shock absorbing properties.

An article of footwear (10) that includes a liner (30), an upper (14), and an insert (50). The liner has an inward surface (31) that encloses an inner void (18) for accommodating a foot, and an outward surface (32) that defines a rear shaft portion (38), a heel portion (36), and a sole portion (35). The upper has a midsole portion (42), and surrounds the rear shaft portion, the sole portion, and the heel portion of the liner. The insert is formed as a single body of material with increased hardness and stiffness relative to the upper. This insert is arranged between the liner and the upper, and includes a protruding portion (54), a heel counter (56), and a shank (58). The protruding portion extends upwards from the heel counter and along the rear shaft portion, and provides a guiding trajectory for a heel during insertion into the inner void.

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.

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 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.

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.

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.

The present invention relates to a method for the production of plastic footwear (10; 100) of the full plastic type by means of moulding using a polyurethane mixture (M; P). The method comprises the steps of: providing a mould (20) having a mould cavity (22) defined by at least two impressions (28, 30) and designed to receive a shoe last (24) so as to define, when the mould (20) is closed, an interspace (26) having the shape and dimensions of the plastic footwear (10; 100) to be produced; spraying a polyurethane mixture (M, P) onto said at least two impressions (28, 30) of the mould cavity (22); inserting the shoe last (24) inside said mould cavity (22); closing the mould cavity (22) so that the sprayed polyurethane mixture (M, P) occupies said interspace (26); opening the mould (20), once at least the demoulding time (td) for the sprayed polyurethane mixture (M, P) has lapsed, such that the sprayed polyurethane mixture (M, P) has solidified inside the interspace (26) forming said plastic footwear (10, 100); extracting the shoe last (24) from the mould cavity (22); removing the plastic footwear (10, 100) from the shoe last (24).

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.