A bonded mesh composite panel can be used to form a three-dimensional upper shell that includes extensions used for double-lasting and/or to otherwise provide a shelf to support foam padding. The foam padding may be, e.g., a foam midsole. The extensions of the upper shell may be located in a lower portion of the shell and may be bonded to the foam midsole in a heel, midfoot and/or forefoot regions.

A sockliner for a shoe may be formed to include an integral fabric skirt. The fabric skirt may remain loose from the sockliner along at least a portion of the periphery of the sockliner. The loose periphery of the fabric skirt may be used to join the sockliner to other shoe components, as in a strobel-type seam.

A method includes positioning a first polymer sheet on a substantially first flat surface of a tool, positioning a second polymer sheet on the first polymer sheet, and moving a second substantially flat surface of the tool into contact with the second polymer sheet. The method also includes maintaining a gap between the first polymer sheet and the second polymer sheet at a predetermined area and heating one of the two substantially flat surfaces of the tool to heat one of the first polymer sheet and the second polymer sheet. The method further includes joining the first polymer sheet and the second polymer sheet together at locations outside of the predetermined area to define a peripheral bond of the chamber.

The present invention relates to an enhanced method for the manufacture of a plastic component (135), in particular a cushioning element for sports apparel, the method comprising: opening a mold (100) by a predetermined amount into a loading position, wherein the mold comprises at least two mold parts (110, 112) and wherein the amount by which the mold is opened influences an available loading volume of the mold, loading a material comprising expanded particles (130) into the loading volume, closing the mold into a closed position, wherein during closing of the mold the mold parts are moved together over different distances (140) in different areas of the mold, compressing the expanded particles by closing the mold and fusing at least the surfaces of the expanded particles to mold the plastic component.

A method of manufacturing a skate boot shell, and more particularly a non-lasted skate boot shell, including shaping tridimensional outer and inner sub-shells, and bonding the shaped sub-shells together through lamination. The lamination is performed after the sub-shells are shaped and includes applying heat to the sub-shells and/or pressure on one of the sub-shells toward the other against a mold surface. A skate boot shell with multiple sub-shells is also discussed, including an outer sub-shell, and inner sub-shell and a reinforcement sub-shell.

An upper shell panel may be placed between first and second sections of a mold. The first section may include one or more expansion cavities and the second section may include one or more pour cavities. A foam-producing chemical mixture may be delivered into the one or more pour cavities and the mold may be closed. The delivered foam-producing chemical mixture may be allowed to expand within the closed mold and to force regions of the upper shell panel into the one or more expansion cavities. The upper shell panel may then be removed from the mold subsequent to the expansion of the delivered mixture.

A full length composite plate to be used as part of an outsole assembly in an article of footwear is disclosed. The full length composite plate comprises a composite material that has a certain percent elongation. The full length composite plate can include a heel cup for heel stability and improved traction. The full length composite plate also can include two angled portions along an arch region that provide arch support, as well as two flattened edges along the arch region to minimize or eliminate buckling. The forefoot region can be relatively flatter than the arch and heel regions, and notches are preferably included along a portion of the forefoot to increase flexibility.

A method for making a cleated plate member for an article of footwear is described. The method includes a number of steps where various molds are used to form different components of the cleated plate member. A collar receptacle is formed using a first molding process. A cleat member is formed from a non-compatible material with a fastener of the cleat member associated with the collar receptacle using another molding process to form a combined cleat assembly. The combined cleat assembly is placed into corresponding receptacles in a mold used to form the cleated plate member. The cleated plate member is formed using another molding process that embeds the collar receptacle into the body of the cleated plate member. The completed cleated plate member includes releasably attached cleat members.

A method for making a cleated plate member of an article of footwear includes forming a blade cleat assembly having an anchor member associated with a blade member, the blade member having a planar body, the body having a base portion, a head portion opposite the base portion, and a through hole formed in the base portion, a first molding material of the anchor member surrounding the base portion of the blade member and extending through the through hole formed in the base portion of the blade member, and associating the blade cleat assembly with an exposed surface of a plate body to form a cleated plate member. The base portion of the blade member further may include a pair of opposing shoulder flange portions. A blade cleat assembly may be disposed in a cleat assembly receptacle of a mold system configured to form a cleated plate member.

Molded rubber objects may be molded and de-molded by defining both a desired final form for the molded rubber object and a tab extending from the final form of the molded rubber object using a cavity in a mold. Rubber pellets may be dispensed in predetermined amounts at desired location(s) within the cavity to provide the rubber needed to form the molded rubber object. Heat and pressure may be applied to the mold to cause the rubber pellets to fill the cavity defining both the desired final form of the molded rubber object and the tab. After the heat and pressure has been applied, a gripping device may grasp the tab and move the tab in a direction and with sufficient force to peel the rubber object from the mold cavity. If desired, the tab may be removed from the molded rubber object.