Abstract: A shoe cushioning system having a thin midsole, a first forefoot element, a second forefoot element and a heel element is described. The first forefoot element is connected to the midsole near the front of the forefoot region, the second forefoot element is connected to the midsole near the rear of the forefoot region, and the heel element is connected to the midsole in the heel region. The first and second forefoot elements are separated by a flex zone. The first forefoot element, second forefoot element and heel element each comprise an elastically deformable cushion with substantially planar top and bottom sides, and an attached cap structure. The first forefoot element may have a curved front edge and a substantially linear rear edge, wherein the curved front edge approximately follows the curved line defined by the metatarsal heads of the metatarsus bones of the foot.

Abstract: The process of molding a component of a sole unit for an athletic shoe comprising the steps of supporting a core of a first plastic material in a cavity of a mold, the core defining an integral part of the component and extending within a heel region toward a forefoot region, supporting at least one rigid plug member within the cavity juxtaposed and in partially surrounding relation to the core, injecting a second plastic material into the cavity to fill the cavity, to form a shell around the core, at least partially curing the injected plastic material, removing the plug member, and injecting a third plastic material which upon curing forms a second resilient plastic material having a hardness (Shore A) greater than that of the material of the core into the cavity to fill the area heretofore occupied by the plug member, the plug member being shaped such that the third plastic material forms a set of posts.

Abstract: The invention is in a sole unit for footwear including a midsole/wedge component (16, 30, 40, 60) of plastic material. The midsole/wedge component includes a core (26, 36, 46, 62) which may be characterized as a V-channel within a central longitudinal portion extending away from the back of the heel along substantially the longitudinal axis of the component. A pair of posts (22 and 24, 32 and 34, 42 and 44, 64 and 66) describing a lateral and medial post extend along the component at least to the region of the heel seat of the wedge. The density of the medial post (Shore A) may be equal to or greater than the density of the lateral post, and both posts have a density (Shore A) greater than that of the core to minimize excessive rear foot motion and instability.The invention also envisions several process for forming the midsole/wedge component.