Abstract: A footwear sole includes shock absorbing elements that extend from upper and lower plates. In one embodiment, the shock absorbing elements include a bridge defining a plurality of receptacles extending from the lower plate and a plurality of protrusions extending from the upper plate. Each protrusion is associated with one receptacle, and a portion of each protrusion extends into the receptacle.

Abstract: A method of manufacturing an article of footwear having a direct attach sole component includes providing an upper and a receptacle shell that defines a receptacle adapted to receive a cushion insert. A molding insert is placed into the receptacle, and the upper is joined with the receptacle shell. A mold is closed about the receptacle shell and at least a portion of the upper to form a mold cavity corresponding to the direct attach sole component. Material is introduced into the mold cavity to form the direct attach sole component. The mold insert protects the shell from deformation during the molding process. The mold insert is removed and replaced with a cushioning insert after the molding process. The footwear can optionally include a partially transparent shell that supports a sole component that receives a cushion insert, such that the cushion insert and/or sole component are visible through the shell.

Abstract: A convertible garment that is reconfigurable from a garment to a neck pillow. The neck pillow may be generally U-shaped to fit about the neck of a wearer. The garment may include a pocket generally corresponding in shape to desired shape of the neck pillow. The pocket is of sufficient size to receive the remainder of the garment so that the remainder of the garment can be inserted into the pocket. The pocket may be sized so that the remainder of the garment substantially fills the pocket, thereby providing a relatively firm neck pillow capable of providing the desired level of neck support. The pocket may have a closure, such as a zipper, to retain the remainder of the garment in the pocket. The garment may be a jacket with the pocket located in the lower back that opens to the inside of the garment. The pocket may be manufactured from or lined with a soft material, such as a brushed tricot or a fleece.

Abstract: A sole component having a base, a toe cover and an integral line of articulation permitting the toe cover to be molded in an “open” position and moved into a “closed” position during assembly on the article of footwear. The line of articulation may include a line of reduced thickness extending laterally across the sole. The line of articulation may also include breaks defined in the sidewall of the sole in alignment with the line of reduced thickness. The present invention also provides a method of forming a sole component generally including the steps of providing a mold having bottom and top mold parts shaped to cooperatively define a mold cavity in the shape of a sole component having a toe cover joined to a base along a line of articulation, closing the mold parts, injecting a sole forming material into the cavity, removing the sole component and moving the toe cover about the line of articulation into a closed configuration for use.

Abstract: A footwear construction including a portion of an upper and/or sole, a strap defining a sleeve, and a cord joined with the upper and/or sole portion, extending toward the strap and slidably housed in the sleeve. An adjustment element is selectively locatable along a part of the cord. By sliding the cord relative to the sleeve and optionally adjusting the location of the adjustment element, the spatial relationship between the strap and the upper and/or sole portion can be selectively adjusted to accommodate a particular dimension of a wearer's foot and/or ankle. A method is also provided for manufacturing footwear including the above components.

Abstract: A method of manufacturing footwear includes providing a modular forepart and a modular rearpart, overlapping these parts along an overlap margin a preselected distance, and permanently joining the parts to selectively manufacture footwear of at least two different sizes, for example, a full size or a half size or some other partial size. The forepart and rearpart can be injection molded from one or more polymeric materials in a mold. The polymeric materials can be bonded to a sheet of material which can be at least partially retained in a three-dimensional, contoured shape by the polymeric material. The molded polymeric material can form a supportive and/or structural exoskeleton in an upper portion of the footwear. The exoskeleton can define one or more holes through which the sheet is visible to form one or more aesthetic regions on the upper. An article of footwear constructed with the method is also provided.

Abstract: A method for manufacturing footwear including injection molding a polymeric material on a sheet of material in preselected locations and/or in a preselected pattern so that the polymeric material bonds to the sheet and forms a structural exoskeleton of an upper of the footwear. The upper can be joined with a sole. The polymeric material can be injection molded on the sheet while the sheet is in a planar or flat configuration, and subsequently, the sheet and bonded exoskeleton can be conformed to a three-dimensional configuration of an upper. Additional polymeric materials can be injected on the exoskeleton to reinforce certain areas of the same. The exoskeleton can define one or more holes through which the sheet is visible to form one or more aesthetic regions on the upper. An article of footwear constructed with the method is also provided.

Abstract: A method of manufacturing footwear includes providing a modular forepart and a modular rearpart, overlapping these parts along an overlap margin a preselected distance, and permanently joining the parts to selectively manufacture footwear of at least two different sizes, for example, a full size or a half size or some other partial size. The forepart and rearpart can be injection molded from one or more polymeric materials in a mold. The polymeric materials can be bonded to a sheet of material which can be at least partially retained in a three-dimensional, contoured shape by the polymeric material. The molded polymeric material can form a supportive and/or structural exoskeleton in an upper portion of the footwear. The exoskeleton can define one or more holes through which the sheet is visible to form one or more aesthetic regions on the upper. An article of footwear constructed with the method is also provided.

Abstract: A footwear construction including an upper, a midsole including a midsole flange, and an outsole shell including an outsole flange. The flanges can project outwardly, away from the upper in the forefoot portion. The flanges can be joined with a direct attach bond and a lock stitch. The flanges can each terminate short of the heel portion. The lock stitch can terminate short of the heel portion, and can be visible above and below the joined flanges. The midsole can include a fully exposed and viewable portion in the heel portion of the footwear. The midsole can include a heel cup integrally formed with the midsole flange. A method for constructing the footwear includes direct attaching a midsole to an upper and an outsole including an outsole flange. The midsole can form with a midsole flange, and the midsole flange and outsole flange can be stitched together with a lock stitch.

Abstract: An impact absorbing material for a footwear article includes a first sheet having a plurality of projections for dispersing the force of an impact and a second sheet, having a lower durometer than the first sheet, that is bonded to the first sheet for absorbing the force from the projections. The projections are arranged on the first sheet such that nonlinear gaps are formed between adjacent pairs of projections. The impact absorbing material may be positioned between an upper and an inner liner of the footwear article and may be selectively positioned on the footwear article to protect an area on the wearer that is vulnerable to impact, such as the wearer's feet, ankles, heels or calves.

Abstract: A welted footwear construction with a direct-attach outsole and an internal tray containing a low density cushioning material. The welt may be secured to the upper and insole by one line of stitching and to the tray by a second line of stitching. The tray may include separate heel and forefoot cavities, each containing a low density cushioning material. The tray may be manufactured from thermoplastic urethane (“TPU”) and may contain low-density polyurethane (“PU”). The low-density PU may be molded in place within the cavities in the tray. The outsole may be directly attached to the undersurface of the tray, and may be manufactured from high-density PU.

Abstract: A footwear construction including a sole and an adjustable heel element selectively rotatable about an axis of rotation to configure the heel element in a fitness mode or a stability mode. The heel element can include a ground contacting surface having a first performance contour and a second, different performance contour. In the fitness mode, the first performance contour is positioned rearward of the second performance contour to provide a rolling/rocking motion when the heel region of the footwear engages a walking surface in a gait cycle. In the stability mode, the second performance contour is positioned rearward of the first performance contour to provide a stable impact when the heel region engages a walking surface. The footwear can include an actuator to enable the heel element to rotate and locking elements to hold the heel element in a fixed rotational position. A related method of use also is provided.

Abstract: A footwear construction including a portion of an upper and/or sole, a strap defining a sleeve, and a cord joined with the upper and/or sole portion, extending toward the strap and slidably housed in the sleeve. An adjustment element is selectively locatable along a part of the cord. By sliding the cord relative to the sleeve and optionally adjusting the location of the adjustment element, the spatial relationship between the strap and the upper and/or sole portion can be selectively adjusted to accommodate a particular dimension of a wearer's foot and/or ankle. A method is also provided for manufacturing footwear including the above components.