A footwear construction includes a midsole including a lateral sidewall and a medial sidewall, and a mesh substrate layer covering the lateral sidewall and medial sidewall to protect the surfaces of those sidewalls from abrasion, wear and damage, and in some cases to provide tuned stiffness to the sidewalls and thus the midsole. The mesh substrate layer can wrap partially above and below the midsole so that edges of the layer can be conceals between the midsole and an upper, or between the midsole and an outsole layer. The mesh substrate can include a mesh material and a film sheet bonded to one another, with the film sheet facing the midsole and the mesh textile facing outward in the finished footwear. A related method of manufacture also is provided.

A footwear construction includes a midsole including a lateral sidewall and a medial sidewall, and a mesh substrate layer covering the lateral sidewall and medial sidewall to protect the surfaces of those sidewalls from abrasion, wear and damage, and in some cases to provide tuned stiffness to the sidewalls and thus the midsole. The mesh substrate layer can wrap partially above and below the midsole so that edges of the layer can be conceals between the midsole and an upper, or between the midsole and an outsole layer. The mesh substrate can include a mesh material and a film sheet bonded to one another, with the film sheet facing the midsole and the mesh textile facing outward in the finished footwear. A related method of manufacture also is provided.

The present invention relates to a mould (10) for producing footwear (1) by means of direct injection onto the 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 (14), a pair of second half-rings (16), a first cover (18), a second cover (20) and a mould last (22). In accordance with the invention the mould (10) comprises gripping means (24) designed to fix selectively the first half-rings (14) to the base (12) or to the second half-rings (16). The present invention also relates to a method for producing footwear (1) using said mould (10).

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.

An article of footwear has an upper that is direct attached with the sole. The direct attach sole has an insert, such as an airbag, that forms a portion of a sidewall. The insert is externally visible and forms at least a portion of an external sidewall of the sole. The insert is formed into the direct attach sole by having the insert or a mask temporarily joined with the insert contact a sidewall molding surface of a mold used in the direct attach operation such that the insert results in forming a visible element of the direct attached sole.

Sole structures including a plate including a first polyolefin resin, and an edge portion comprising a second resin are disclosed herein. The edge portion is more flexible or less rigid than the plate. Articles of footwear formed from the sole structures are also provided. Methods of making the polyolefin resin compositions, plates, edge portions, sole structures, and articles of footwear are also provided. In some aspects, the first polyolefin resin composition includes an effective amount of a polymeric resin modifier.

Sole structures including a plate including a first polyolefin resin, and an edge portion comprising a second resin are disclosed herein. The edge portion is more flexible or less rigid than the plate. Articles of footwear formed from the sole structures are also provided. Methods of making the polyolefin resin compositions, plates, edge portions, sole structures, and articles of footwear are also provided. In some aspects, the first polyolefin resin composition includes an effective amount of a polymeric resin modifier.

The present disclosure describes molded footwear including a sole integrally connected to an upper. For example, a sole structure may include an insole and a strobel board. The insole may include a spacing structure that rests on a top surface of the strobel board to form a cavity between the insole and the strobel board. Further, the upper and/or strobel board may include perforations at least partially aligned with the cavity. Accordingly, the sole structure may be connected to the upper via injection molding material into the cavity formed between the insole, the strobel board, and the upper. The molding material may flow through the specifically located perforations in the shoe's upper and/or the shoe's strobel board such that the material bonds internally within the cavity, internally within the perforations, and externally to the shoe's upper and strobel board but within the mold cavity.

The present invention describes a shaped footwear device intended to be used as a supportive insole or orthotic and a system and methods for making the same. The footwear device includes a top foam layer, a light-cured composite material layer, and a bottom textile layer. The footwear device is created by conforming a pre-cured insole assembly to the plantar surface of a foot or foot mold and then exposing the pre-cured insole assembly to light to create a shaped footwear device with a light-cured composite material support plate.

The present invention describes a shaped footwear device intended to be used as a supportive insole or orthotic and a system and methods for making the same. The footwear device includes a top foam layer, a light-cured composite material layer, and a bottom textile layer. The footwear device is created by conforming a pre-cured insole assembly to the plantar surface of a foot or foot mold and then exposing the pre-cured insole assembly to light to create a shaped footwear device with a light-cured composite material support plate.