Methods for preparing a footwear article are disclosed herein. An example method may comprise disposing resin adjacent a mold, disposing a lattice structure in at least a portion of the resin disposed adjacent the mold, closing the mold using a lasted upper, injecting foam into the closed mold such that the foam operates to couple the lasted upper and the lattice structure together.

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.

Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding, or injection molding followed by compression molding.

Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding, or injection molding followed by compression molding.

Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding, or injection molding followed by compression molding.

Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding, or injection molding followed by compression molding.

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.

An injection-molding process for injecting a shoe soling including at least two adjacent injection-molding layers onto a shoe upper drawn over a shoe last, uses a mold cavity including a frame, the cavity being covered at the top by the upper also serving as a mold cover, with plastic material being injected into the cavity below the upper. To produce two adjacent injection-molding layers of plastic materials having different properties and reaction times in one operation, i.e. without needing an interim mold opening, before covering the cavity a film is clamped over it by a clamp mounted on the frame. When filling the cavity, the space below the film is first filled with plastic material to produce the first injection-molding layer and then, to produce the adjacent second injection-molding layer, the space above the film is filled with plastic material. Plastic materials are used that inseparably attach to the film.

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 mould (10) for producing footwear (1) by direct injection onto an upper (2) of a sole (3), comprising a tread (5) and a midsole (4), wherein the midsole (4) is composed of a first layer (6) and a second layer (7). The mould (10) comprises a base (12), a pair of first half-rings (16), a lid (18), a pair of second half-rings (20) and a mould last (22). The first half-rings (16) are designed to be arranged close together such that they abut against the base (12) and against the lid (18), so as to form a first mould cavity for moulding the first layer (6) of the midsole (4). While the first half-rings (16) are abutting against the base (12), the second half-rings (20) are designed to be arranged close together, such that they lie over the half-rings (16) and abut against the upper (2), fitted onto the mould last (22), so as to form a second mould cavity for moulding the second layer (7) of the midsole (4). In accordance with the invention the first half-rings (16) are provided with guiding means (24) so that they can be moved away from and towards each other and rotate about an axis of rotation (C). The invention also relates to a method for producing footwear by direct injection onto an upper, which may be performed by means of the mould according to the invention.