Abstract: A method for forming a molded article having an insert includes temporarily protecting features of the insert during a molding process using a malleable plugging material. In one step, the method includes disposing a plug including the plugging material within a receptacle of the insert, where each receptacle includes an engagement feature. The insert and the plugging material are placed into a mold, and a liquid molding material is applied to an exterior surface of the insert. The liquid molding material is solidified, forming the molded article including the insert embedded in the solidified molding material. The molded article is removed from the mold, and the plugging material is removed from the receptacle of the insert that is embedded in the molded article to expose the engagement feature.

Abstract: A method for forming a molded article having an insert includes temporarily protecting features of the insert during a molding process using a malleable plugging material. In one step, the method includes disposing a plug including the plugging material within a receptacle of the insert, where each receptacle includes an engagement feature. The insert and the plugging material are placed into a mold, and a liquid molding material is applied to an exterior surface of the insert. The liquid molding material is solidified, forming the molded article including the insert embedded in the solidified molding material. The molded article is removed from the mold, and the plugging material is removed from the receptacle of the insert that is embedded in the molded article to expose the engagement feature.

Abstract: A method for forming a molded article having an insert includes temporarily protecting features of the insert during a molding process using a malleable plugging material. In one step, the method includes disposing a plug including the plugging material within a receptacle of the insert, where each receptacle includes an engagement feature. The insert and the plugging material are placed into a mold, and a liquid molding material is applied to an exterior surface of the insert. The liquid molding material is solidified, forming the molded article including the insert embedded in the solidified molding material. The molded article is removed from the mold, and the plugging material is removed from the receptacle of the insert that is embedded in the molded article to expose the engagement feature.

Abstract: An article of footwear is made by (a) providing a component having a contaminant on a receiving area of a surface; (b) blast cleaning the receiving area of the surface by propelling an abrasive alkali, alkaline earth, or ammonium compound in a pressurized gas stream against the receiving area; (c) applying a pressurized gas stream free of the abrasive compound, liquid water, and organic liquid to the receiving area to remove any residual abrasive compound from the receiving area of the surface to produce a cleaned receiving area; (d) applying a layer of material to the cleaned receiving area, wherein the material is selected from the group consisting of adhesives and coating compositions; and (e) incorporating the component into an article of footwear.

Abstract: Foam items may be buffed using particles such as particulate sodium bicarbonate in accordance with the present invention. Foam items may be, for example, expanded EVA foam items pre-formed into an intermediate size and shape. A skin layer may be formed during the expansion of the foam item to form an expanded foam item which may be entirely or partially removed by buffing the item using particles projected with selected buffing parameters. The buffing parameters may be varied based upon the thickness of at least a portion of the skin layer and/or the desired degree of moldability for the foam item after buffing. Particulate sodium bicarbonate or other types of particles used for buffing may be recycled and reused for further buffing of foam items.

Abstract: An article of footwear is made by (a) providing a component having a contaminant on a receiving area of a surface; (b) blast cleaning the receiving area of the surface by propelling an abrasive alkali, alkaline earth, or ammonium compound in a pressurized gas stream against the receiving area; (c) applying a pressurized gas stream free of the abrasive compound, liquid water, and organic liquid to the receiving area to remove any residual abrasive compound from the receiving area of the surface to produce a cleaned receiving area; (d) applying a layer of material to the cleaned receiving area, wherein the material is selected from the group consisting of adhesives and coating compositions; and (e) incorporating the component into an article of footwear.

Abstract: An article of footwear is made by (a) providing a component having a contaminant on a receiving area of a surface; (b) blast cleaning the receiving area of the surface by propelling an abrasive alkali, alkaline earth, or ammonium compound in a pressurized gas stream against the receiving area; (c) applying a pressurized gas stream free of the abrasive compound, liquid water, and organic liquid to the receiving area to remove any residual abrasive compound from the receiving area of the surface to produce a cleaned receiving area; (d) applying a layer of material to the cleaned receiving area, wherein the material is selected from the group consisting of adhesives and coating compositions; and (e) incorporating the component into an article of footwear.

Abstract: Foam items may be buffed using particles such as particulate sodium bicarbonate in accordance with the present invention. Foam items may be, for example, expanded EVA foam items pre-formed into an intermediate size and shape. A skin layer may be formed during the expansion of the foam item to form an expanded foam item which may be entirely or partially removed by buffing the item using particles projected with selected buffing parameters. The buffing parameters may be varied based upon the thickness of at least a portion of the skin layer and/or the desired degree of moldability for the foam item after buffing. Particulate sodium bicarbonate or other types of particles used for buffing may be recycled and reused for further buffing of foam items.

Abstract: An article of footwear is made by (a) providing a component having a contaminant on a receiving area of a surface; (b) blast cleaning the receiving area of the surface by propelling an abrasive alkali, alkaline earth, or ammonium compound in a pressurized gas stream against the receiving area; (c) applying a pressurized gas stream free of the abrasive compound, liquid water, and organic liquid to the receiving area to remove any residual abrasive compound from the receiving area of the surface to produce a cleaned receiving area; (d) applying a layer of material to the cleaned receiving area, wherein the material is selected from the group consisting of adhesives and coating compositions; and (e) incorporating the component into an article of footwear.