Described are methods for manufacturing a sole, in particular, a sole for a sports shoe, comprising providing at least one first sole element (110; 210) and at least one second sole element (130; 230); and injecting at least one second sole element (130; 230) through the at least one first sole element (110; 210). Also described are methods for manufacturing a shoe, in particular a sport shoe, wherein the method comprising: providing a flexible sock element (350; 450; 521) and at least one sole element (380; 480; 570); injecting the at least one sole element (380; 480; 570) on the flexible sock element (350; 450; 521), such that the at least one sole element (380; 480; 570) comprises a stiffening element (385; 485; 575) below the arch of the foot.

A molding system and a method for forming a sole structure are provided. The method includes flowing a molten polymeric material into a mold from an upstream device, receiving the molten polymeric material in a cavity of the mold, and maintaining a repeatable, uniform pressure profile as the molten polymeric material is delivered into the mold.

A manufacturing method of an injection molded composite shoe sole and the sole thereof are provided. The method includes facial modifying, cleaning a combination face of an additional component formed of a material different from the sole material, and coating a facial process layer on the combination face, and drying to modify the combination face; gumming, placing a gum layer on the facial process layer on the modified combination face; in-mold positioning, placing additional component into a mold; and injection molding, injecting the sole material into the mold, thereby gumming the sole material and the gum layer of the combination face to form a composite shoe sole. Therefore, the manufacturing method effectively reduces the sole manufacturing time.

The present invention relates to an improved outsole and method for making the same. In many embodiments, the improved outsole includes an integrally connected rigid material within a toe cap. In many embodiments a mold is provided which aids in the production of the improved outsole by pressing a first and second raw material around the rigid material to form the outsole. The improved outsole provides increased flexibility, comfort, and durability to a shoe which uses the outsole, and greatly improves the protection to the wearer of said shoe.

Method for applying an insert 40 of polymer material onto a support layer 30, 30a, comprising the following steps: providing a mould 10 comprising at least one base 12 and at least one cover 18; the base 12 and the cover 18 being suitable for defining with the facing surfaces 13, 17, when the mould 10 is closed, a mould impression 16 which is delimited perimetrally by a closing edge 14; spraying a polymer mixture M in the fluid state onto one of the two facing surfaces 13, 17 of the mould 10; introducing the support layer 30, 30a between base 12 and cover 18 of the mould 10 so that, when the mould 10 is closed, the support layer 30, 30a projects from the closing edge 14; pressing the cover 18 of the mould 10 onto the base 12; opening the mould 10 in order to remove the support layer 30, 30a and the associated insert 40; trimming the portion S of the polymer mixture M which, following the spraying and pressing steps, has flowed outside the external perimeter of the impression mould 16. Finally, the invention relates to a mould 10 which can be used to implement this method and the articles 20 which may be obtained by means of this method.

A footwear apparatus includes a primary outsole having a primary cavity, a secondary outsole connected to the primary, outsole and having a secondary cavity, a midsole movably disposed over the primary outsole and secondary outsole including a primary protrusion extending at least partially within the primary cavity, and a tertiary outsole disposed about the primary protrusion. The footwear apparatus defines a z-axis through the secondary cavity and substantially normal to a ground surface, a y-axis extending substantially from the secondary cavity to the primary cavity, and an x-axis substantially normal to a plane created by the z-axis and the y-axis. The midsole is configured to rotate substantially about the x-axis, rotate substantially about the y-axis, to resist rotation substantially about the z-axis. The footwear apparatus is adaptive to a around surface orientation on which the wearer walks and to rotational movements of the wearers body.

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.

An article of footwear includes a sole structure including a polymeric bladder element enclosing a fluid-filled interior cavity. The bladder element has a surface with a groove that extends generally parallel with a transverse edge from a lateral side to a medial side, and has a reduced thickness at the groove. A first length along a longitudinal midline of the bladder element from a longitudinal extremity of the bladder element to the groove corresponds with a first footwear size, and a second length along the longitudinal midline of the bladder element from the longitudinal extremity to the transverse edge corresponds with a second footwear size larger than the first footwear size. The sole structure is used in a method of manufacturing an article of footwear.

A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.

An article of footwear may include an upper forming a void within the footwear, a sole structure secured to the upper, and a chamber that encloses a pressurized fluid. The sole structure includes a depression. The chamber is located within the void of the upper and located on the depression of the sole structure. The chamber may include a plurality of fluid-filled subchambers, a manifold, and a connection fluidically-connected at least one of the subchambers to the manifold. The subchambers may enclose the pressurized fluid at different pressures. The subchambers may be separated from one another by a bonded area in the direction extending between the heel and toe of the chamber.