Described are methods for manufacturing a plastic component, in particular a cushioning element for sports apparel, a plastic component manufactured with such methods, for example a sole or a part of a sole for a shoe, and a shoe with such a sole. The method for the manufacture of a plastic component includes loading a mold with a first material includes particles of an expanded material and fusing the surfaces of the particles by supplying energy. The energy is supplied in the form of at least one electromagnetic field.

The present invention is a composite sole used in footwear. The composite sole comprises of two components, a foot support that suspends the foot and a structural chassis. The foot support is a flexible material that attaches to the perimeter of the structural chassis and conforms to the foot. The structural chassis provides rigidity and the foot support provides sufficient strength to suspend the foot during rigorous physical activity. The chassis and foot support performs similarly to that of a trampoline; however, its function has a plurality of features not found in a trampoline. The structural chassis is designed to provide a multitude of physical and performance characteristics in the heel, arch, forefoot and toe area to assist in pronation, plantar support, energy return, upper shoe comfort, toe-off and cushion at impact. The structural chassis has air vents, allowing air to enter and the foot support includes perforations allowing this air to ventilate the underside of foot.

A sole structure for an article of footwear includes a first cushioning member extending continuously from an anterior end of the sole structure to a posterior end of the sole structure. The first cushioning member includes an upper side, a bottom side formed on an opposite side from the upper side, and a recess formed in the upper side. A first bladder is disposed within the recess adjacent to a lateral side of the sole structure and a second bladder is disposed within the recess adjacent to a medial side of the sole structure.

A reinforcement structure is disposed on a midsole of a shoe. A first bar extends from a first point in a medial side of the midsole to a second point in the medial side of the midsole. The second point is closer to a toe of the shoe than the first point. A second bar extends from a third point in the medial side of the midsole to a fourth point in a lateral side of the midsole. The fourth point being closer to the toe of the shoe than the third point. A third bar extending from a fifth point in the medial side of the midsole to a sixth point in the lateral side of the midsole. The sixth point being closer to the toe of the shoe than the fifth point. The third bar extending further toward the toe of the shoe than the second bar.

A fluid-filled chamber, which may be incorporated into articles of footwear and other products, may include an outer barrier and a tensile element. The outer barrier may have a first portion, an opposite second portion, and an interior surface defining an interior void. The tensile element may be secured to the first portion of the outer barrier in a plurality of first bond areas and may be secured to the second portion of the outer barrier in a plurality of second bond areas. Each of the bond areas may be connected to portions of the tensile element spaced from the interior surface.

A fluid-filled chamber, which may be incorporated into articles of footwear and other products, may include an outer barrier and a tensile element. The outer barrier may have a first portion, an opposite second portion, and an interior surface defining an interior void. The tensile element may be secured to the first portion of the outer barrier in a plurality of first bond areas and may be secured to the second portion of the outer barrier in a plurality of second bond areas. Each of the bond areas may be connected to portions of the tensile element spaced from the interior surface.

An article may include a first polymeric material layer having a surface. A first conductive trace may form at least a portion of the first layer surface. The article may further include a second polymeric material layer. The second layer may have a first surface, a portion of the second layer first surface being bonded to a portion of the first layer surface. The second layer may have a portion of a channel defined therein, the channel at least partially coinciding with a portion of the first conductive trace. The article may also include a first patch interposed between the first layer surface and the second layer first surface. The first patch may span the channel and cover a portion of the first conductive trace.

Sole structures (e.g., midsoles and/or outsoles) and articles of footwear include heel-supporting areas and/or forefoot-supporting areas that include a central area (e.g., a central recessed area) and a plurality of surrounding rings. Additionally or alternatively, the sole structures (e.g., midsoles and/or outsoles) may include bands of material defined by recessed grooves to provide a bumpstop type impact-force attenuating structure.

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.

An article of footwear includes a fitting system with an upper member that is supported by the upper and a strand guide that is supported by the sole structure. The strand guide is flexible and flexes in concert with the sole structure. The strand guide has a guide surface. The fitting system further includes a tensioning system with a flexible strand that is configured to bias the upper member toward the strand guide. The flexible strand has a first section coupled to the upper member and a second section extending through the sole structure. The second section abuts the guide surface. The second section is configured to slide across the guide surface as a result of flexure of the strand guide. The first section and the upper member are configured to move relative to the sole structure as a result of sliding of the second section across the guide surface.