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.

Articles of footwear including a thermo-molded upper having a skin composed of one or more low melting point thermoplastic polymers. The skin may include at least one of: a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The uppers may be formed by placing a skin and an inflatable bladder into a mold cavity and heating the mold to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.

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 ground surface orientation on which the wearer walks and to rotational movements of the wearers body.

A shoe comprising an outsole, where the outsole is comprised of a rubber composition comprised of (A) diene-based elastomer comprising: (1) from about 20 to about 45 phr of high Tg SSBR pre-extended with vegetable oil, wherein said SSBR has a Tg in a range of from about −20° C. to about +10° C. and a bound styrene content in a range of from about 25 to about 50 percent and a vinyl 1,2-content in a range of from about 10 to about 80 percent based on butadiene content, (2) from 55 to about 80 phr of at least one additional diene-based elastomer comprising of at least one of polybutadiene, cis 1,4-polyisoprene rubber, and acrylonitrile-butadiene rubber, and (B) about 20 to about 70 phr of reinforcing filler comprised of a combination of carbon black and silica where the filler is comprised of from about 50 to about 100 weight percent silica.

A method of manufacturing a wearable article may include providing a modular mold assembly that defines a mold cavity. The modular mold assembly may include a base and a first removable mold tool that interfits with the base. The base may have a mold surface partially defining the mold cavity and the first removable mold tool may have a mold surface disposed at and further defining the mold cavity of the modular mold assembly. A topography of the mold surface of the first removable mold tool may be nonuniform and different than a topography of the mold surface of the base. The method may include disposing polymeric material at the mold cavity, and then thermoforming a bladder in the mold cavity from the polymeric material. The bladder may have an outer surface with a nonuniform topography imparted by the topography of the mold surface of the first removable mold tool.

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 footwear article forming process, and a device for the same are disclosed. The process includes: providing a forming mold set including an outer modular mold, an inner formation mold, and a footwear-forming space therebetween. The footwear-forming space comprises a footwear lower portion forming space and a footwear main portion forming space. Footwear article forming steps are as follows: injecting a pre-determined amount of a footwear main portion rubber material into a footwear main portion sprue channel, the footwear main portion rubber material being injected from a footwear main portion rubber injection opening into the footwear main portion forming space via a transfer injection channel; and placing a footwear lower portion rubber material into the footwear lower portion forming space.

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.

Aspects hereof relate to a multi-part mold assembly for use in manufacturing articles. The mold assembly provides for contouring, shaping and cutting materials to form articles via a continuous single processing operation. The mold assembly includes an upper mold portion with a three-dimensional contouring/shaping portion and a first cutting edge, a lower mold portion with a three-dimensional contouring/shaping portion and a second cutting edge, and a base portion into which the lower mold portion may retract during use. Upon application of a first force, the upper and lower mold portions cooperate to contour/shape a material from which an article is to be formed. Upon application of a second force greater than the first, the first cutting edge and the second cutting edge interact to shear the material that extends beyond the respective cutting edges. The result is an article that is contoured, shaped and cut/trimmed utilizing a single processing operation.

A method of forming a sole structure for an article of footwear. The method includes depositing a first outsole material including a first uncured polymeric material upon a mold surface of a mold cavity. The method also includes disposing a midsole element adjacent to the first outsole material within the mold cavity and subjecting the first outsole material and the midsole element to a molding process to form the sole structure having an outsole and a midsole.